wia new range brochure 2014

a CONTENTS

2014

Welding Product Range

Interactive Edition

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CONTENTS

Interactive Edition

SCOTT, DRIVER AND FABRICATOR GaRRY ROGERS MOTORSPORT

MULE, DIRECTOR MaVERICK WELDING

WAYNE, LEAD WELDER aLFaBS GROUP

WAYNE, LEAD WELDER aLFaBS GROUP

BOB, NO 1 FABRICATOR TRIPLE EIGHT RaCE ENGINEERING

Every Welder of Oz has selected and relied on the WIa, Miller and Hobart brands to get the job done. When you’re the best, you only use the best.

THE WELDERS OF OZ AREN’T YOUR AVERAGE FABRICATORS OR BOILERMAKERS, THESE GUYS ARE THE BEST OF THE BEST.

More info welding.com.au/weldersofoz

http://www.welding.com.au/weldersofoz

FOR OVER 50 YEARS, WIA HAS BEEN SUPPLYING THE AUSTRALIAN MARKET WITH PRODUCTS AND EXPERTISE THAT CAN BE RELIED ON TO DELIVER SUCCESS.

Trusted by the Best.


1 CONTENTS

WE KNOW THE MARKETWe work hard to build our knowledge and understand what our market needs. Whether it’s heavy engineering, mining or oil and gas, we know the market.

Global Brands. Local Support.

USED BY THE BESTOur brands are selected by welding professionals and companies who demand the most reliable products, in-depth knowledge and cost-effective solutions.

OUR PRODUCTS50 years of experience gives us the expertise to develop products that deliver!

The Austarc 16TC electrode and Weldmatic Fabricator have been industry icons for decades.

WHERE WE STARTEDEstablished in 1962, WIA began as a small team of welding specialists, working to develop industry leading, innovative products. Today, we are a leading welding supplier because of our innovation and expertise.

OUR APPROACHWe work with our customers to develop the best products and deliver the best solutions. Our customers have trust in our products and company because of how we do things. That’s why we’re trusted by the best.

OUR INDUSTRY EXPERTISEBoth locally and globally our products are developed, delivered and supported by a team of industry experts who understand the needs of our customers.

50YEARS

OUR GLOBAL PARTNERSHIPSWIA is part of the global organisation ITW (Illinois Tool Works), a diversified manufacturing company.

Our global partnerships give us access to the world’s leading welding brands.

OUR BRANDSOur brands include WIA electrodes, wires and equipment; Miller industrial welding equipment; Hobart filler metals and Bernard™ and Centerfire™ consumables.

2 CONTENTS

welding.com.au

Find your local WIA, Miller and Hobart Distributor. View our full

product range at welding.com.au

Download product manuals, data sheets & MSDS.

http://www.welding.com.au/

http://www.welding.com.au

3 CONTENTS

Contents

KEY TO SYMBOLS

Constant Current Output

Constant Voltage Output

alternating, Direct Current Output

Constant Current and Constant Voltage Output

Direct Current Output

Requires Single Phase Supply

Requires Three Phase Supply

Welding Equipment MIG WELDERS - LIGHT INDUSTRIAL .................................................... 6 - 17ENGINE DRIVEN .......................................................................................... 18 - 33ARC & TIG ..................................................................................................... 34 - 41MIG & MULTI-PROCESS .......................................................................... 42 - 55PLASMA CUTTING ..................................................................................... 56 - 59INDUCTION HEATING ................................................................................ 60 - 63WIREFEEDERS ............................................................................................ 64 - 71

Filler MetalsELECTRODES ................................................................................................ 74 - 82WIRES ............................................................................................................ 83 - 91HARDFACING PRODUCTS ...................................................................... 92 - 98

Welding SafetyAUTO-DARKENING HELMETS .............................................................99 - 111VORTEX PAPR SYSTEM ..................................................................... 112 - 113

AccessoriesWATER COOLERS .............................................................................................115DRIVE ROLLERS & INLET GUIDES .................................................. 115 - 116REMOTE CONTROLS ....................................................................................... 117

MIG Guns & ConsumablesMIG GUNS ................................................................................................ 120 - 121CONSUMABLES & REPLACEMENT PARTS ............................... 122 - 129

4 CONTENTS

5 CONTENTS

Welding EquipmentHEAVY DUTY WELDING EQUIPMENT BUILT TO WITHSTAND THE HARSHEST ENVIRONMENTS AND CONDITIONS.

6 CONTENTS

7 CONTENTS

MIG Welders Light Industrial

PRODUCT THICKNESS OF MATERIAL TO BE WELDED

WELDING OUTPUT APPLICATIONS

SINGLE PHASE

Weldmatic 190

190 amps @ 23.5 Volts, 15% Duty Cycle

Home workshops, trades, light industry, rural & hire fleets

Weldmatic 270


Light industrial, medium fabrication, rural workshops, hire fleets, body shops & maintenance

Weldmatic 270C


Light industrial, workshops, body shops & maintenance

THREE PHASE

Weldmatic 356

355 amps @ 32 Volts, 40% Duty Cycle225 amps @ 23.5 Volts, 100% Duty Cycle

Light to medium industrial fabrication, sheet metal, boat building, service, repair, maintenance & training centres/schools, & stainless steel & aluminium

Weldmatic 396


Medium to heavy fabrication, training centres/schools, stainless steel & aluminium

Weldmatic Fabricator


Medium to heavy fabrication including vehicle manufacture, ship building, aluminium & stainless steel construction, & the full range of steel fabrication

THIN

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8 CONTENTS

WELDMATIC IS KNOWN FOR ITS EXTREME RELIABILITY & PROFESSIONAL PERFORMANCE. FROM THE HEAVY DUTY DRIVE SYSTEMS TO THE INDUSTRIAL QUALITY GUNS, EVERY COMPONENT IS SELECTED & ENGINEERED TO ENSURE EACH WELDMATIC MACHINE PERFORMS.

Weldmatic - Built to Perform

9 CONTENTS

3 YEAR GOLD SHIELD WARRANTYEvery Weldmatic

machine is backed by WIa’s industry leading ‘Gold Shield 3 Year Warranty’, covering parts and labour, and supported by an australia wide service network. You can be guaranteed you’re buying reliability and performance.

TOOL TRAYFold down tool tray provides storage for gun contact tips and nozzles.

SUPERIOR INDUCTANCE TECHNOLOGYWeldmatic machines have been engineered to deliver smooth arc performance right across the welding range.

LOW GAS CYLINDER TRAYThe low, easy to access rear tray, allows the gas bottle to be rolled on and off with ease, eliminating the need for lifting.

QUICK & EASY GUN CABLE CONNECTIONall Weldmatic machines are supplied with an industrial quality gun and cable, complete with euro connector for easy fitting and removal.

FAN-ON-DEMAND COOLINGBy only operating when needed, the fan uses less power and generates less noise. The result is a reduction in dust build-up inside the machine, meaning less maintenance time and longer component life.

FEATURE PACKED 4RD WIREFEEDERW64 wirefeeder enables custom set-up to suit the job – including arc start, low wire speed, burnback, spot time, trigger latch, inch, purge, and pre and post gas.

GAS OR GASLESS Suited to both gas shielded solid wires and gasless (self-shielding) flux cored wires. Industrial front mount strength connectors make the switch between shielded and gasless wires quick and easy.

DUAL FRONT HANDLESDual handles make it easy to move your Weldmatic around the workshop, plus provide handy storage for interconnecting work leads.

HEAVY DUTY 4 ROLL DRIVE SYSTEMNow with larger, stronger gears and ball bearings to further enhance the reliability and performance of Weldmatic machines.

EASY SCREW SPOOL HUBEvery Weldmatic features the easy screw spool hub, allowing quick installation of 5 and 15kg spools.

HEAVY DUTY TRANSFORMEREngineered for reliability, the heavy duty transformer delivers a smooth, consistent weld performance.

3 YEA

R

10 CONTENTS

MIG

PRIMARY VOLTAGE

RATED PRIMARY CURRENT

MAX. PRIMARY CURRENT

RECOMMENDED GENERATOR kVA

SUPPLY PLUG

RATED OUTPUT @ 40C (10 min)

WELDING CURRENT RANGE

WIRE SIZE RANGE (MM)

SHIPPING WEIGHT

240 Vac - 50Hz

15 amps 36 amps 10 kVa 15 amps

190 a, 23.5 V, 15% Duty Cycle145 a, 21.2 V, 25% Duty Cycle72 a, 17.5 V, 100% Duty Cycle

30 - 190 amps

0.6 - 0.9 solid 0.8 - 1.2 cored

40kg

PORTABLE & POWERFULWith the highest output in its class, the 190 will weld thicker materials, and handle a wider range of applications than normally expected from this size of machine.

IDEAL FOR A WIDE RANGE OF APPLICATIONSFrom the home user and rural workshop, to light fabrication and hire fleets.

QUICK & EASY GUN CABLE ASSEMBLYSupplied with a tradesman quality gun and cable complete with euro connector for easy fitting and removal.

EASY SET-UP & ADJUSTMENT9 Voltage settings for precise welding control and weld setting chart for easy set-up and fine tuning of the machine.

GAS OR GASLESS Suits gas shielded and gasless flux cored wires.

WELDS UP TO 8MM Fillet weld up to 8mm of steel, stainless steel or aluminium.

BUILT-IN OPERATOR SAFETYThe power source features a built-in thermal protection device that will activate if the machine is operated beyond its safe thermal operating zone.

WELDMATIC WORKSHOP [OPTIONAL] P/N aM353.

GAS BOTTLE TROLLEY [OPTIONAL] P/N aM340.

PORTABLE AND POWERFUL.

8MM

PACKAGE INCLUDES

3m Euro Gun Cable3m Work LeadGas RegulatorDrive Rollers: 0.6/0.8mm “V” groove; 0.9/1.2mm knurled (gasless)Tips: 0.6/0.8/0.9/1.2ES6 Sample Wire 0.8mm

Weldmatic 190Part No: CP131-0

11 CONTENTS

Weldmatic Workshop™

Part No: aM353 [Mobile Welding Trolley for Weldmatic 190]

MIG

CUSTOMISED SUPPORT PLATEDesigned to secure the Weldmatic 190 to the trolley for maximum stability.

CABLE HANGERSUse the cable hangers to keep the work lead, gun cable and supply lead tidy.

HEAVY DUTY WHEELSIndustrial quality wheels and castors deliver smooth operation and durable performance to move your Weldmatic 190 where it’s needed.

GAS BOTTLE TRAYFor easy storage of a gas cylinder, making it easier to move around the workshop. Suits E or D cylinders.

GAS CYLINDER CHAINSDouble chains to secure gas bottle and keep it stable and safe when being moved.

POWDER COATED EXTERIOR PANELSPowder coated panels for long-lasting performance to resist harsh workshop environments.

SHIPPING INFORMATIONWeight: 29kg Dimensions: 68cm long, 43cm wide & 58cm high.

STORAGE AND CONVENIENCE.

EASY SLIDING STORAGE DRAWERSWith two drawers, the deep drawer is perfect for storing your welding helmet and gloves, while the top partitioned tray allows for easy storage and organisation of tips and nozzles.

* Weldmatic 190, gas cylinder and other accessories not included.

12 CONTENTS

Weldmatic 270Part No: CP132-1 - With W64 4 Roll Drive Wirefeeder

FINE ARC CONTROL 16 SETTINGS

PRIMARY VOLTAGE




RATED OUTPUT @ 40C (10 min)



SHIPPING WEIGHT

240 Vac - 50Hz

25 amps 56 amps 13.5 kVa 270 a, 27.5 V, 20% Duty Cycle

30 - 270 amps

0.6 - 1.2 solid 0.8 - 1.2 cored

142kg

240 Vac - 50Hz

15 amps 32 amps 8 kVa 200 a, 24 V, 22% Duty CycleSetting D-1 Max.

30 - 200 amps

0.6 - 1.2 solid 0.8 - 1.2 cored

15 Amp plug fitted for commissioning purposes only. 32 Amp plug to be installed by user to obtain full output.

BIG ON POWER! BIG ON PERFORMANCE!The Weldmatic 270 has the advantage when it comes to both power and performance. Pumping out a huge 270 amps of genuine welding power, this machine outperforms the competition when it comes to welding performance.

WIDE RANGE OF APPLICATIONSThis heavy weight MIG suits light to medium fabrication, rural maintenance and hire fleets.

PACKED WITH PROFESSIONAL FEATURESPacked with all the features you’d expect in an industrial three phase MIG machine, the single phase Weldmatic 270 is for the serious welder who wants results.

GAS OR GASLESSSuits gas shielded and gasless flux cored wires.

SPOOL CAPACITY5kg & 15kg.

WELDS UP TO 12MM Fillet weld up to 12mm of mild steel, stainless steel or aluminium.

LOW GAS BOTTLE TRAYThe low, easy to access rear tray, allows the gas bottle to be rolled on and off with ease, eliminating the need for lifting.

REDUCED POWER CONSUMPTIONThe Fan-on-Demand™ cooling system uses less power and generates less noise by only operating when needed, meaning improved efficiency, less maintenance and a safer working environment.


BIG ON POWER. BIG ON PERFORMANCE.

12MM

PACKAGE INCLUDES

W64 4 Roll Drive Wirefeeder3m Euro Gun Cable5m Work Lead10m Interconnecting LeadsGas Regulator/FlowmeterDrive Rollers: 0.9/1.2mm“V” groove; 0.9/1.2mm knurled (gasless)Tips: 0.6/0.8/0.9/1.2

MIG

13 CONTENTS

Weldmatic 270CPart No: CP136-1 - Compact Package

COMPACT MIG PACKAGECompact MIG with feature packed integrated wirefeeder, enabling custom set-up to suit the job - including arc start, low wire speed, burnback, spot time, trigger latch, inch, purge and pre and post gas.

IDEAL FOR THE WORKSHOP ENVIRONMENTEconomical option for workshops where a separate wirefeeder isn’t required. Works well under a bench.

PORTABLEEasy to move around the workshop, with no messy leads between the power source and wirefeeder.

EASY TO ACCESS CONTROLSall controls are located on the front panel – easy access to all wirefeeder features.

GAS OR GASLESSSuits gas shielded and gasless flux cored wires.


REDUCED POWER CONSUMPTIONThe Fan-on-Demand™ cooling system uses less power and generates less noise by only operating when needed, meaning improved efficiency, less maintenance and a safer working environment.

LOW GAS BOTTLE TRAYThe low, easy to access rear tray, allows the gas bottle to be rolled on and off with ease, eliminating the need for lifting.

COMPACT MIG WITH INTEGRATED WIREFEEDER. IDEAL FOR WORKSHOPS.

PRIMARY VOLTAGE




RATED OUTPUT @ 40C (10 MIN)



PRODUCT HEIGHT

SHIPPING WEIGHT

240 Vac - 50Hz

25 amps 56 amps 13.5 kVa 270 a, 27.5 V, 20% Duty Cycle

30 - 270 amps

0.6 - 1.2 solid 0.8 - 1.2 cored

760mm 810mm (to top of handles)

127kg

240 Vac - 50Hz

15 amps 32 amps 8 kVa 200 a, 24 V, 22% Duty Cycle Setting D-1 Max.

30 - 200 amps

0.6 - 1.2 solid0.8 - 1.2 cored

15 Amp plug fitted for commissioning purposes only. 32 Amp plug to be installed by user to obtain full output.

PACKAGE INCLUDES

3.6m Euro Gun Cable5m Work LeadGas Regulator/FlowmeterDrive Rollers: 0.9/1.2mm “V”; 0.9/1.2mm knurled (gasless)Tips: 0.6/0.8/0.9/1.2


WELDS UP TO 12MM Fillet weld up to 12mm of mild steel, stainless steel or aluminium.

12MM

FINE ARC CONTROL 16 SETTINGS & INTEGRATED WIREDEEDER

MIG

14 CONTENTS


PRIMARY VOLTAGE







SHIPPING WEIGHT

380/415 Vac - 50Hz 3 Phase

15 amps 23 amps 16.5 kVa 355 a, 32 V, 40% Duty Cycle225 a, 25.3 V, 100% Duty Cycle

30 - 355 amps

0.6 - 1.2 solid 0.8 - 1.6 cored

168kg

FLEXIBILITYReach around those awkward jobs with the fully enclosed separate wirefeeder.

DUAL FRONT HANDLESExclusive split handles with rubber grips designed to move the machine easily and allow composite work lead and MIG gun to be stored independently.

FAN ON DEMANDThe Fan-on-Demand™ uses less power and generates less noise by only operating fan when needed. This reduces dust build up inside the machine, meaning less maintenance time and increasing the life of components.

GAS OR GASLESSSuits gas shielded and flux cored wires.


THE CHOICE OF MEDIUM FABRICATION WORKSHOPS.


PURE POWERThis industrial strength MIG delivers 356 amps of pure power, plus all the features needed to maximise your productivity in one complete package.

PRODUCTIVITY ON DEMANDExperience a boost in productivity thanks to the impressive 40% duty cycle at the rated output of 32 Volts.

INDUSTRIAL STRENGTHThe Weldmatic 356 is the ideal choice for medium industrial fabrication workshops, sheet metal, boat building, service, repair, maintenance and training centres/schools.

RELIABILITYFitted with an industrial standard 3.6m gun and cable for reliable welding performance and long operating life.

FINE ARC CONTROL30 Voltage steps provide fine arc control over the whole operating range, from short arc to full spray transfer.

PACKAGE INCLUDES

W64 4 Roll Drive Wirefeeder3.6m Euro Gun CableBernard™ Centerfire™ Tip 0.9mm10m Work Lead10m Interconnecting LeadsGas Regulator/FlowmeterDrive Rollers: 0.9/1.2mm “V” groove; 0.9/1.2mm knurled (gasless, flux cored)

COMES WITH BERNARD™ CENTERFIRE™ CONSUMBLES

MIG

15 CONTENTS



PRIMARY VOLTAGE







SHIPPING WEIGHT

380/415 Vac - 50Hz3 Phase

15 amps 27 amps 20 kVa 395 a, 34 V, 30% Duty Cycle250 a, 26 V, 100% Duty Cycle

19 - 395 amps

0.8 - 1.6 solid 0.8 - 1.6 cored

172kg

COMPLETE INDUSTRIAL MIG WELDING PACKAGEThis 396 amp three phase MIG welder is ideal for medium to heavy fabrication, and all general industrial fabrication applications.

FLEXIBILITY & POWEROptimal weld characteristics provide high quality results on steel, stainless steel and aluminium, plus the power to comfortably run all popular sizes of solid and flux cored wires. With the capacity to run

1.6mm flux cored wire, the 396 can handle a wide range of applications.


FINE ARC CONTROL30 Voltage steps for fine arc control over the whole operating range, from short arc to full spray transfer.

DUAL FRONT HANDLESExclusive split handles with rubber grips designed to move the machine easily and allow the composite work lead and MIG gun to be stored independently.

DIGITAL METERSDigital Volt and amp meters retain last weld information and allow precise set-up.

ULTRA-FAST WIRE BRAKING FEATUREFeatured on the 4RD wirefeeder - leaves the wire tip extra clean at the end of the weld.Features include: ‘Normal’ and Creep’

start speed modes. Cold wire inch/

gas purge controls. Pre/post gas

timer controls.



COMPLETE INDUSTRIAL MIG WELDING PACKAGE.

PACKAGE INCLUDES

W64 4 Roll Drive Wirefeeder3.6m Euro Gun CableBernard™ Centerfire™ Tip 0.9mm10m Work Lead10m Interconnecting LeadsGas Regulator/FlowmeterDrive Rollers: 0.9/1.2mm “V”, 0.9/1.2 knurled (gasless, flux cored, metal cored)

MIG

16 CONTENTS

THE WELDMATIC FABRICATOR HAS BEEN THE INDUSTRY STANDARD FOR OVER 30 YEARS WITH PROVEN PERFORMANCE & RELIABILITY THAT IS SECOND TO NONE.

The Complete Industrial Welding MIG Solution.

MIG

Weldmatic FabricatorPart No: CP135-1 - W64 4 Roll Drive Wirefeeder

17 CONTENTS

PRIMARY VOLTAGE







SHIPPING WEIGHT

415 Vac - 50Hz3 Phase

18 amps 30 amps 20 kVa 400 a, 34 V, 45% Duty Cycle270 a, 27.5 V, 100% Duty Cycle

40 - 400 amps

0.6 - 1.6 solid 0.8 - 2.0 cored

200kg

THE COMPLETE INDUSTRIAL WELDING SOLUTION.

APPLICATIONSa complete industrial welding solution for medium and heavy industrial fabrication, including: Vehicle manufacture. Ship building. aluminium and

stainless steel construction. Full range of steel

fabrication.

RUGGED & RELIABLEThis compact MIG has the power to comfortably run all popular sizes of solid and flux cored wires.


SPOOL CAPACITYaccommodates 5kg & 15kg spools – meaning greater flexibility across a range of applications.

PRECISE SET-UP & CONTROL Digital Volt and amp

meters with last weld displayed for 30 seconds for precise set-up. The separate ON/OFF

switch enables weld settings to be retained. 30 step Voltage controls

enable fine tuning of weld settings for precise welding control.

REDUCED POWER CONSUMPTION & LESS NOISEFan-on-Demand™ cooling system uses less power and generates less noise by only operating when needed, meaning improved efficiency, less maintenance and a safer working environment.


PACKAGE INCLUDES

W64 4 Roll Drive Wirefeeder3.6m Euro Gun CableBernard™ Centerfire™ Tip 0.9mm10m Work Lead10m Interconnecting LeadsGas Regulator/FlowmeterDrive Rollers: 0.9/1.2mm “V”; 0.9/1.2mm knurled (gasless, flux cored, metal cored)

SETTING THE INDUSTRY STANDARD FOR OVER 30 YEARS


18 CONTENTS


MULE, DIRECTOR MAVERICK WELDING



19 CONTENTS

PRODUCT PROCESS AUXILIARY OUTPUT

STD. GENERATOR POWER - WATTS (PEAK)

WELDING OUTPUT RANGE

ENGINE VRD RCD AUX POWER OULETS

TYPICAL APPLICATIONS

Bobcat 250 [Petrol]

3/16" (4.8 mm)

11,000 40 - 250 aC 40 - 250 DC 17 - 28 CV

Kohler Petrol

2 x 15 amp1 x 32 amp(all 240V)

Fabrication, Maintenance, Rural, Construction

Bobcat 250 [Diesel]

3/16" (4.8 mm)

11,000 40 - 250 aC 40 - 250 DC 17 - 28 CV

Kubota Petrol

Opt. 2 x 15 amp1 x 32 amp(all 240V)

Fabrication, Structural, Maintenance, Repair, Piping

Trailblazer 325 [Petrol]

3/16" (4.8 mm)

12,000 10 - 325 DC 10 - 35 CV

Kohler Petrol

Opt. 2 x 15 amp Sockets(all 240V)

Fabrication, Maintenance, Rural, Construction

Trailblazer 325 [Diesel]

3/16” (4.8 mm)

12,000 10 - 325 DC 10 - 35 CV

Kubota Petrol

Opt. 2 x 15 amp Sockets(all 240V)

Fabrication, Structural, Maintenance, Repair, Piping

Big Blue 400X Pro

1/4" (6 mm)

12,000 20 - 400a CC14 - 40V CV

CaT Diesel

2 x 15 amp1 x 32 amp (all 240V)

Fabrication, Maintenance, Structural, Construction

Big Blue 600X

3/8" (9.5 mm)

5,500 20 - 600 DC 14 - 40 CV

Deutz Diesel

2 x 15 amp Sockets

Construction, Structural, Maintenance

Big Blue 700X Duo Pro

1/2” (13 mm)

5,500 3P4,000 1P

Paralleled 40 - 800aEach Side 20 - 400a

Deutz Turbo Diesel

2 x 15 amp 240V 1PH1 x 32 amp 380V 3PH

Construction, Pipeline, Mining, Maintenance, Railroad

Big Blue air Pak

1/2" (13 mm)

5,500 1P 20 - 750 DC 14 - 40 CV

Deutz Turbo Diesel

2 x 15 amp Sockets

Construction, Mining, Maintenance, Railroad

Big Blue 800 Duo air Pak

1/2” (13 mm)

1PH=15kW3PH=27kW

20 - 800 CC 14 - 40 CV

Deutz Turbo Diesel

2 x 15 amp 240V 1PH1 x 32 amp 400V 3PH

Construction, Structural, Maintenance, Mining

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* Optional wirefeeder required Capability Designed for this process

Engine Driven


20 CONTENTS

BOBCAT 250 PETROL

ENGINE BRAND & WARRANTY

HP TYPE WELD SPEED

IDLE SPEED

FUEL CAPACITY

OIL CAPACITY

STANDARD SHUTDOWNS

Kohler: 3-year Manufacturer’s Warranty

23 HP Twin-cylinder, four-cycle over-head valve, industrial air-cooled, gasoline (carburettor)

3600 RPM

2300 RPM

45 L 1.4 L Low Oil Pressure

BOBCAT 250 DIESEL


HP TYPE WELD SPEED

IDLE SPEED

FUEL CAPACITY

OIL CAPACITY

STANDARD SHUTDOWNS

Kubota: 2-year 2000 hours one year minor components

19 HP at 3600 RPM

Three-cylinder, industrial liquid-cooled, diesel

3600 RPM

2450 RPM

45 L 3.2 L High Coolant Temperature, Low Oil Pressure, Low Fuel

TRAILBLAZER 325 (PETROL)


HP TYPE WELD SPEED IDLE SPEED

FUEL CAPACITY

OIL CAPACITY

STANDARD SHUTDOWNS

Kohler: 3-year Manufacturer’s Warranty

25 HP at 3600 RPM

Twin-cylinder, four-cycle overhead valve, industrial air-cooled, gasoline (carburettor)

Auto-Speed™ 2400, 2800, 3200 or 3600 RPM

2400 RPM

45 L 1.4 L Low Oil Pressure

TRAILBLAZER 325 (DIESEL)


HP TYPE WELD SPEED IDLE SPEED

FUEL CAPACITY

OIL CAPACITY

STANDARD SHUTDOWNS

Kubota: 2-year 2000 hours one year minor components

24.8 HP at 3600 RPM

3-cylinder, industrial liquid-cooled, diesel

Auto-Speed™2400, 2800, 3200 or 3600 RPM

2400 RPM

45 L 3.7 L High Coolant Temperature, Low Oil Pressure, Low Fuel

BIB Blue 400X PRO

ENGINE BRAND

HP TYPE FEATURES ENGINE SPEEDS

CAPACITIES AUTOMATIC ENGINE SHUTDOWN

Caterpillar C1.5

21.7 3-cylinder, industrial liquid-cooled, diesel

EPa Tier 4i compliant, indirect-injected, liquid-cooled engine.Right-side service access with intervals of 250 hrs for oil and filters.

1850 RPM weld

Fuel: 43.5 LOil: 5.7 LCoolant: 5.7 L

Low Oil Pressure, High Coolant Temperature, Low Fuel Level

Engine Specs

ENGINE DRIVEN

21 CONTENTS

BIG BLUE AIR PAK - ENGINE

ENGINE BRAND



Deutz TD2011L04w

63.4 Four-cylinder, industrial, liquid (oil) cooled engine

EPa Tier 4i compliant, turbocharged, direct-injected, liquid-cooled (oil) engine. Right-side service access with 500 hr intervals for oil and filters.

1850 Run1250 Idle

Fuel - 95 LOil - 10.4 L


BIG BLUE 800X DUO AIR PAK

ENGINE BRAND



Deutz TD2011L04o

63.4 Turbo-charged four-cylinder, liquid-cooled industrial diesel

EPa Tier 4i compliant Idle: 1350 RPMWeld: 1800 RPM

Fuel: 95 LOil: 10.4 L Coolant: Integrated Oil


BIG BLUE AIR PAK – COMPRESSOR

COMPRESSOR BRAND

FEATURES FREE AIR DELIVERY AT 1850 RPM

FREE AIR DELIVERY AT 1235 RPM

WORKING PRESSURE CONSTANT

DUTY CYCLE

OIL CAPACITY

AUTOMATIC COMPRESSOR SHUTDOWNS

Ingersoll Rand CE55 G1

Rotary screw with electric clutch for on/off.Oil change intervals 500 hrs (same as engine).Life expectancy 30,000 hrs.

60 cfm(1.70 m³ /min)

40 cfm(1.13 m³ / min)Idle

100 PSIG 7 bar

100% 4.7 L Oil Temperature

BIG BLUE 800X DUO AIR PAK - COMPRESSOR

COMPRESSOR BRAND

FEATURES FREE AIR DELIVERY AT 1850 RPM

FREE AIR DELIVERY AT 1235 RPM

WORKING PRESSURE CONSTANT

DUTY CYCLE

OIL CAPACITY

AUTOMATIC COMPRESSOR SHUTDOWNS

Ingersoll Rand CE55 G1

Rotary screw with electric clutch for on/off.Oil change intervals 500 hrs (same as engine). Life expectancy 30,000 hrs.

60 cfm(1.70 m³ /min)

40 cfm(1.13 m³ / min) Idle

100 PSIG 7 bar

100% 3.79 L Oil Temperature

22 CONTENTS

Bobcat 250Part No: MR907500001-1 [Kohler Petrol Engine]

QUIETER. SMALLER. LIGHTER.

REDESIGNED

REVERSED GENERATOR AIRFLOWExclusive engine and generator packaging design operates cooler and more efficiently. The engine is rotated towards the front to create more efficient airflow. More efficient airflow and exclusive engine location are significant contributors to reduced sound level and size. Hot air recirculation is eliminated when machine is mounted in tight spots, and internal parts are kept cool for optimal performance.

Up to

33% Sound Reduction

12cm Shorter Up to

24kg

Lighter

IMPROVED! UP TO 33% QUIETER Significant improvements

in sound level and quality offer better jobsite communication, making for a safer work environment. The engine has been

rotated toward the front to create efficient airflow and quieter operation. Now you can start the job earlier and work around hospitals, businesses and residential areas.

IMPROVED! SMALLER & LIGHTER DESIGNTakes up less space on trucks and trailers - leaving more room on your truck for other equipment and tools.

ENGINE DRIVENENGINE DRIVEN

23 CONTENTS

LONG RUNTIMESLarge 45L fuel capacity means many hours of run time before refuelling.

VERSATILE AC AND DC WELD OUTPUTProvides quality welds on all types of metals. DC is smooth and easy to run while aC Stick is used when arc blow occurs.

MULTI-PROCESS CAPABILITYMIG, Stick, DC, aC, TIG

AUXILIARY OUTPUT* 2 X 15 amp Sockets. RCD. 1 X 32 a 240 V 1PH 60Hz.

IMPROVED! EASIER MAINTENANCEMaintenance is now faster and easier. With front panel maintenance displays, you know when your equipment needs to be serviced. Oil checks can be performed from

the top by the front panel. Single-side fuel fill and oil drain/filter. Tool-less panels that allow for quick access.

SMOOTH GENERATOR POWER Revolutionary ten

degree skewed rotor design optimises generator performance. Typical equipment which

can be run includes hand tools, circular saw, air compressor and flood lights.

3 YEAR WARRANTYWelder/generator is warranted by Miller for 3 years, parts and labour. For details, refer to Miller’s True Blue warranty statement. Engine is warranted separately by engine manufacturer.

Air filter

Oil level checkOil fill

Oil filter Oil drain

Fuel fill

Fuel filter

APPLICATIONS PROCESSES

MaintenanceRepairRuralFabricationStructural Steel WorkStand-alone Generator

Stick (SMaW)Flux-Cored (FCaW)MIG (GMaW)DC TIG (GTaW)air Carbon arc (CaC-a)Cutting and Gouging (4.8mm carbons)air Plasma Cutting and Gouging with Optional Spectrum Models

WELDING MODE

PROCESS AMP/VOLT RANGE

RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)

WEIGHT (WITHOUT FUEL)

CC/aC Stick/TIG 40 - 140 a 60 - 160 a 80 - 225 a

225 a at 25 V, 100% Duty Cycle

Peak: 11,000 WattsContinuous: 9,500 Watts44 a, 240 VaC, 60 Hz

H: 711H: 832 (to top of exhaust)W: 508D: 1029

227kg

CC/DC Stick/TIG 100 - 250 a 250 a at 25 V, 100% Duty Cycle

CV/DC MIG/FCaW 17 - 22 V 20 - 28 V


*Generator auxiliary power is 60Hz, and intended for operating equipment associated with welding, such as angle grinders, drills and floodlights. Some Australian 50Hz equipment incorporating induction motors, such as pumps, fans, air compressors, refrigeration or air-conditioners, may not operate correctly and could be damaged. Refer to appliance supplier or manufacturer to confirm suitability.

24 CONTENTS

Bobcat 250Part No: MR907565001-1 [Kubota Diesel Engine]Part No: MR907565001-2 (with VRD) [Kubota Diesel Engine]

IMPROVED DESIGN. NOW SMALLER & LIGHTER.

IMPROVED! SMALLER & LIGHTER DESIGNTakes up less space on trucks and trailers - leaving more room on your truck for other equipment and tools.

IMPROVED! EASIER MAINTENANCEWith front panel maintenance displays, you know when your equipment needs to be serviced.

LONG RUNTIMESLarge 45L fuel capacity means many hours of run time before refuelling.

VERSATILE AC AND DC WELD OUTPUTProvides quality welds on all types of metals. DC is smooth and easy to run while aC Stick is used when arc blow occurs.

DESIGNED FOR RELIABILITY Copper windings and

iron generator components for a quality built machine. Lugged - not soldered

- heavy internal leads for better field durability. Superior cooling

technology for maximum performance and engine life. Super-tough armour

to protect the welder/generator from accidental impact. Lift hook integrated into

the centre frame, which bolts to the machine’s base for greater durability.

MULTI-PROCESS CAPABILITYMIG, Stick, DC, aC, TIG.

SMOOTH GENERATOR POWERRevolutionary ten degree skewed rotor design optimises generator performance. Typical equipment which can be run includes hand tools, circular saw, air compressor and flood lights.

WELDING MODE


RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)


CC/aC CC/DC

Stick/TIG 40 - 130 a 60 - 160 a 80 - 225 a 100 - 250 a




289kg

CV/DC MIG/FCaW 17 - 22 V 20 - 28 V



MaintenanceRepairRuralFabricationStructural Steel WorkStand-alone Generator

Stick (SMaW)Flux-Cored (FCaW)MIG (GMaW)DC TIG (GTaW)Non-Critical (GTaW)air Carbon arc (CaC-a)Cutting and Gouging (4.8mm Carbons)air Plasma Cutting and Gouging with Optional Spectrum Models

Up to

24kg

Lighter

AUXILIARY OUTPUT* 2 X 15 amp Sockets. RCD. 1 X 32 a 240 V 1PH 60Hz.


ENGINE DRIVEN


25 CONTENTS

Trailblazer 325Part No: MR907510001-1 [Kohler Petrol Engine] Part No: MR907566001-1 [Kubota Diesel Engine]Part No: MR907566001-2 (with VRD) [Kubota Diesel Engine]

NEW PETROL MODEL - NOW 49KG LIGHTER. NEW DIESEL MODEL - NOW 46KG LIGHTER.

WELDING MODE


RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)


CC/DC Stick/TIG 10 - 325 a 325 a at 28 V (Petrol) 325 a at 33 V (Diesel), 100% Duty Cycle

Peak: 12,000 WattsContinuous: 10,500 Watts240V, 60Hz


209kg (Petrol model)281kg (Diesel model)CV/DC MIG/FCaW 10 - 325 V 325 a at 28 V (Petrol)

325 a at 33 V (Diesel), 100% Duty Cycle

DUAL GENERATOR SYSTEMOne for welding and one for generating power - meaning no interaction between tools and the welding arc.

4-POLE 3 PHASE WELDING GENERATORUtilises a 4-pole, 3-phase generator to produce the best welding arc.

ACCU-RATED™ 12,000 WATTS OF USABLE PEAK POWERSeparate 12,000 Watt single phase generator cranks out enough power for most applications.

SUPERIOR ARC PERFORMANCE Three Stick modes –

XX10, XX18 and Gouge. Two wire modes – Solid

& Flux Cored. Excellent MIG/FCaW arc

performance. Lift-Arc™ TIG with Auto-

Crater™ and Auto-Stop™ and Pulse.

SELF-CALIBRATING DIGITAL METERS Preset and actual

amperage/Voltage. Process settings. Maintenance functions:

hour meter, oil change interval and RPMs.

AUTO-SPEED™ TECHNOLOGY Traditional high speed

welder/generators always run at maximum speed (3600 RPM) while welding. auto-Speed technology automatically adjusts the engine speed to match your actual weld load requirements. When more power is

needed, the engine will automatically ramp up. By automatically varying the engine speed, fuel consumption and costs are reduced.

INNOVATIVE DESIGNFor quieter operation, reduced size and weight and easier maintenance.

SUPER-TOUGH PROTECTIVE ARMOUR WITH COVERSHigh-impact resistance in all temperatures and is chemical-resistant.

AUXILIARY POWER (MR907510001-1)* 2 X 15 amp Sockets. RCD.



Structural Steel WorkSheet MetalRepairRentalPipeFabricationMaintenance

Stick (SMaW)MIG (GMaW)Flux Cored (FCaW)DC TIG/Pulsed TIG (GTaW-P)air Carbon arc (CaC-a) air Plasma Cutting and Gouging with Optional Spectrum Models

ENGINE DRIVEN


26 CONTENTS

Big Blue® 400X ProPart No: MR907630-1 [CaT Diesel Engine]

SUPERIOR ARC PERFORMANCE Four pre-set DIG

settings (Stick). Hot Start™ (Stick). Lift-arc™ TIG with

auto-Stop™ and Crater-out. MIG/FCaW arc

performance.

AUTO REMOTE SENSE™

Detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/ panel switch.

QUIET OPERATIONImproves work site communication.

SIMPLE-TO-SET CONTROLSNo elaborate procedure, just select process and weld!

THE VAULTUltimate control board reliability. Solid-state control technology, housed in a sealed vault. The vault's sealed connections are made through watertight plugs that make these components impenetrable to dust and moisture.

CATERPILLAR HEAVY DUTY LOW-SPEED INDUSTRIAL ENGINEDesigned to operate for 10,000 hours before the first basic overhaul.

METER MAINTENANCE DISPLAYS Fuel gauge. Hour meter function. Oil change interval. High coolant temperature

low oil pressure shut downs. Low fuel shutdown -

engine shuts down before system runs out of fuel, making restarts easy.

AUXILIARY POWER* 2 X 15 amp Sockets. 1 x 32 amp Socket. RCD.

VRD TO CAT C AS1674.2

3 YEAR WARRANTY Welder/generator is warranted by Miller for 3 years, parts and labour. For details, refer to Miller’s True Blue warranty statement. Engine is warranted separately by engine manufacturer.

WELDING MODE

AMP/VOLT RANGE

RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)

WEIGHT* (WITHOUT FUEL)

CC/DC 20 - 400 a 300a at 32 VDC, 100% Duty Cycle350a at 27 VDC, 100% Duty Cycle400a at 24 VDC, 100% Duty Cycle


H: 813W: 667D: 1422

Net: 458kgShipping: 481kg*Additional 37kg when fuel tank is full

CV/DC 14 - 40 V

MODEL OPTIONS PART NO

With VRD, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907630-2

With VRD, Roll Frame & Spill Tray assembly, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907630-3


Mechanical ContractorsStructural SteelworkFabricationMaintenanceRepairRentalConstruction

Stick (SMaW)MIG (GMaW)Flux Cored (FCaW)DC TIG (GTaW)air Carbon arc (CaC-a)Rated: 4.8mm (3/16 in) Carbons, Capable: 6.4mm (1/4 in) Carbonsair Plasma Cutting and Gouging with Optional Spectrum Models

ENGINE DRIVEN


27 CONTENTS

Big Blue® 600XPart No: MR907192-1 [Deutz Diesel Engine]

WELDING MODE

AMP/VOLT RANGE

RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)


CC/CV/DC 20 - 600 a 500 a at 25 V, (20 kW), 100% Duty Cycle550 a at 34 V, (18.7 kW), 60% Duty Cycle600 a at 30 V, (18 kW), 40% Duty Cycle


H: 1092W: 724D: 1654

Shipping: 769kg*Additional 86kg when fuel tank is full

THREE-PHASE ROTATING FIELD Efficiently produces smooth DC weld output using 20 – 30% less fuel than a rotating armature-type DC generator.

ENCLOSED ROBUST CASE DESIGNProtects internal components from impact and allows air flow to cool and prolong the life of the engine. also reduces sound levels.

ARC-DRIVE™ automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the electrode from going out.

HOT-START™ Provides positive Stick electrode starts making it easy to start all types of electrodes and it also works great for bead tie-ins.

DESIGNED FOR FLEET OWNERS THAT DEMAND THE ULTIMATE IN RELIABILITY.

REMOTE TOOL-LESS OIL DRAINallows oil to be drained without getting under the engine and reduces the chance of oil spillage.

QUICK AND EASY MAINTENANCESingle-side access to oil level check, oil fill, oil filter, fuel filter and air cleaner.

HEAVY-DUTY LOW SPEED INDUSTRIAL DIESEL ENGINEDesigned, built and proven to operate over 10,000 hours before the first basic overhaul.

WEATHERPROOF LEXAN® NAMEPLATEResists cracking and fading, and is color-coded for ease of operation.

AUXILIARY POWER* 2 X 15 amp Sockets. RCD.


METER MAINTENANCE DISPLAYS Fuel gauge. Hour meter function. Oil change interval. High coolant

temperature and low oil pressure shutdowns. Low fuel shutdown -




Heavy ConstructionStructural SteelMaintenance and Repair RigsMining MaintenanceProcess PipingSheet Metal

Stick (SMaW)MIG (GMaW)Flux Cored (FCaW)DC TIG (GTaW)Submerged arc (SaW)air Carbon arc (CaC-a)

ENGINE DRIVEN


28 CONTENTS

Big Blue® 700X Duo Pro Part No: MR907520001-1 (with dual VRD) [Deutz Diesel Engine]

INDEPENDENT AUXILIARY GENERATOR One 5500 Watt peak/

4000 Watt continuous 240V single phase generator, regardless of weld output. Second generator provides

27,000 Watts peak/20,000 Watts continuous 3 phase power (380 - 415V).

700A SINGLE ARC CAPABILITY Two outputs can be

paralleled, providing a single 700a output. Suitable for arc air

Gouging or Sub arc Process.

Dual Operator Engine Drive with 3 Phase Power.MULTI-ARC WELDING IS NOW SIMPLER & MORE VERSATILE.

ENCLOSED ROBUST CASE DESIGNProtects internal components from impact and allows air flow to cool and prolong the life of the engine, while reducing sound levels.

HOT-START™Provides positive Stick electrode starts making it easy to start all types of electrodes, plus it works well for bead tie-ins.

QUICK AND EASY MAINTENANCESingle-side access to oil level check, oil fill, oil filter, fuel filter and air cleaner.

DCCCCV

2 ARCS3 PHASE POWER

ENGINE DRIVEN

29 CONTENTS

REMOTE TOOL-LESS OIL DRAINallows oil to be drained without getting under the engine and reduces the chance of oil spillage.

HEAVY-DUTY LOW SPEED INDUSTRIAL DIESEL ENGINEDesigned, built and proven to operate over 10,000 hours before the first basic overhaul.



temperature and low oil pressure shutdowns. Low fuel shutdown –


STANDARD FEATURES INCLUDE:Stick, MIG, Flux Cored, Lift-Arc™ TIG and digital preset weld meters, output contactor control and automatic idle.

WELDING MODE

AMP/VOLT RANGE

RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)


CC/DC 40 – 800 a(Paralleled)

500 a at 40 VDC, 100% Duty Cycle700 a at 28 VDC, 60% Duty Cycle

Peak: 5500 WattsContinuous: 4000 WattsThree-phase: 27 kW Peak/20 kW Continuous orSingle-Phase: 19 kW Peak/12 kW Continuous

H: 1092 mmH: 1270 mm (to top of exhaust)W: 724 mmD: 1654 mm

Net: 784kgShipping: 799kg*Additional 86kg when fuel tank is full

20 – 400 a(Each Side)

300 a at 32 VDC, 100% Duty Cycle (Each Side)400 a at 36 VDC, 40% Duty Cycle (One Side only)

CV/DC 14 – 40 V(Paralleled)

500 a at 39 VDC, 100% Duty Cycle700 a at 28 VDC, 60% Duty Cycle

14 – 40 V(Each Side)

300 a at 29 VDC, 100% Duty Cycle(Each Side)400 a at 34 VDC, 40% Duty Cycle(One Side only)

AUXILIARY POWER*

1 x 380 V 32 amp Sockets. 2 X 240 V 15 amp Sockets. RCD.

VRD TO CAT C AS1674.2.




Dual VRD, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907520001-2

Dual VRD, Roll Frame & Spill Tray assembly, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907520001-3


Mining Maintenance Cross Country PipelinesProcess Piping Structural SteelHeavy Construction

Stick (SMaW)

Flux Cored (FCaW)

MIG (GMaW)

DC TIG (GTaW)

air Carbon arc (CaC-a)

30 CONTENTS

Big Blue® Air Pak™

Part No: MR907062011-1 [Deutz Diesel Engine] [VRD < 1 sec] Part No: MR907062011-4 [Deutz Diesel Engine] [VRD < 300 m sec] Part No: MR907062011-5 [Deutz Diesel Engine] [No VRD]

THE VAULT Ultimate control board reliability. Solid-state control technology, housed in a sealed vault. The vault's sealed connections are made through watertight plugs that make these components impenetrable to dust and moisture.

Weld. Air. Power.A COMPLETE MOBILE WELDING, AIR & POWER WORKSHOP FOR ON-SITE MAINTENANCE & FABRICATION.

ULTRA-RELIABLE INDUSTRIAL ROTARY SCREW AIR COMPRESSORBelt-driven with automatic belt tensioner with a life expectancy of 30,000 hours.

ENGINE DRIVEN

31 CONTENTS

WELDER/GENERATOR/AIR COMPRESSORProvides a go anywhere solution for field jobs requiring welding, gouging or cutting, compressed air and aC power generation.

INDEPENDENT COMPRESSOR CONTROLSOn/off switch for applications not requiring compressed air. at idle speed will produce 100 PSI at 40 CFM.

ENCLOSED ROBUST CASE DESIGN Protects internal components from impact and allows air flow to cool and prolong the life of the engine. also reduces sound levels.


LOW MAINTENANCEEasy single-side access to engine and 500 hour oil changes for both engine and compressor.

QUIET OPERATORat only 70 dB (95 Lwa) when idle, 79 dB (104 Lwa) at maximum output. Improves work site communications.

HEAVY DUTY LOW- SPEED INDUSTRIAL TURBOCHARGED DIESEL ENGINEProvides ample power at high altitudes.


temperature and low oil pressure shutdowns. Low fuel shutdown –


HOT START™ Provides positive Stick electrode starts to make it easy to start all types of electrodes.

ARC-DRIVE™ automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the electrode from going out.

LOW OCV - VOLTAGE REDUCTION DEVICEProvides open circuit Voltage below 35 Volts for increased operator safety.

INDEPENDENT GENERATOR POWER 4000 Watts of continuous output for lighting and power tools, even while welding at 500 amps.

AUXILIARY OUTPUT*

2 X 240 Volt Sockets. RCD.



WELDING MODE

AMP/VOLT RANGE

RATED OUTPUT

GENERATOR POWER

DIMENSIONS (MM)


CC/DC 20 - 750 a 600 a at 44 V, (26.4 kW), 40% Duty Cycle550 a at 42 V, (23.1 kW) 60% Duty Cycle500 a at 40 V, (20 kW), 100% Duty Cycle

Peak: 5,500 WattsContinuous: 4,000 Watts17 a, 240 VaC, 60 Hz while welding

H: 1092W: 724D: 1654

Net: 876kgShipping: 899kg

CV/DC 14 - 40 V 500 a at 40 V, (20 kW), 100% Duty Cycle

APPLICATIONS

Mining MaintenanceRailroad MaintenanceMaintenance & Repair Rigs

PROCESSES

DC Stick (SMaW)MIG (GMaW)Flux Cored (FCaW)DC TIG (GTaW)Submerged arc (SaW)air Carbon arc (CaC-a) 1/2 in (12.7mm) Carbonsair Compressor


32 CONTENTS

Big Blue® 800X Duo Air Pak™

Part No: MR907536-1 [with VRD]

ENGINE DRIVENENGINE DRIVEN

NEW PRODUCT

AVAILABLE LATE 2014

Built Tough!THREE PHASE POWER. MULTI-ARC WELDING.

MORE POWER33 percent increase in rated output equals 800 amps of weld power and 27,000 watts of generator power.

MULTI-ARC WELDING One dependable engine

— two independent arcs with up to 400 amps each. Or plug in an additional inverter for a true multi operator work platform! Example: One additional

XMT equals 3 operators, up to 240 amps each. Premium quality arcs allow operators to work independently with no arc interaction. Multi operator welding has never been easier or more versatile.

INCREASED EFFICIENCY More arcs and better fuel

economy equal increased profits for your business. Estimated savings are 34

percent with a dual-operator unit versus two single-operator units. Remote oil drain for

engine and compressor prevents spills and makes servicing easy. Electronic engine display

simultaneously displays fuel level, engine hours, coolant temperature, oil pressure, battery Volts, engine RPM, air pressure, and compressor hours. Tracks oil change intervals

and displays engine diagnostics for quick and easy servicing.


Dual VRD, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907536-2

Dual VRD, Roll Frame & Spill Tray assembly, Emergency Stop, Double Pol Battery Isolator & Lockout Device

MR907536-3

2 ARCS AIR3 PHASE POWER

33 CONTENTS

DEUTZ 2011 L04I - HEAVY-DUTY LOW SPEED INDUSTRIAL DIESEL ENGINEDesigned, built and proven to operate over 10,000 hours before the first basic overhaul.

INGERSOLL RAND Ultra-reliable industrial

rotary screw compressor. 30,000-hour life

expectancy. Independent on/off

control for applications not requiring compressed air — allows greater fuel savings and longer compressor service intervals. 100PSI, 60CFM, 100%

Duty Cycle.

VRD STANDARD (CAT.C AS1674.2) Reduces the open-circuit

Voltage to 15 Volts when the welding power source is not in use, increasing operatorsafety without compromising arc starts. Infinite arc control allows

the arc characteristics to be changed for specific applications in Stick, MIG and FCaW.

AUTO REMOTE SENSE™(aRS) detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/panel switch.

AUXILIARY POWER* 1 x 380 V 32 amp Sockets. 2 X 240 V 15 amp Sockets. RCD.

APPLICATIONS

Mining MaintenanceRailroad MaintenanceMaintenance and Repair

PROCESSES

Stick (SMaW)MIG (GMaW)Flux-Cored (FCaW)DC TIG (GTaW)Submerged arc (SaW)air Carbon arc (CaC-a)air Plasma Cutting and GougingCompressed air

THERMAL OVERLOAD PROTECTIONPrevents machine damage if the duty cycle is exceeded or airflow is blocked.

STANDARD FEATURES Digital weld meters. automatic idle. 120 V block heater. Lockout/tagout battery

disconnect switch.

WELDING MODE

OUTPUT MODE

WELD OUTPUT RANGE

WELD OUTPUT RATED AT 104° F (40° C)

MAX OPEN CIRCUIT VOLTAGE

GENERATOR POWER OUTPUT RATED AT 104° F (40° C)

SOUND LEVELS AT 23 FT. (7 M)

DIMENSIONS (MM)


CC/DC (Stick/TIG)

Separate (Dual Outputs)

20 – 400 a

400 a at 36 V, 100% Duty Cycle (Each Side)

85 VDC15 VDC (VRD)

3 phase:27,000 watts peak,20,000 watts continuous1 Phase:5,500 watts peak,4,000 watts continuous

Idle: 73.0 dB (97.8 Lwa),77.2 dB at one meter from front panel

Weld (800 A Load): 81.7 dB (106.5 Lwa), 84.4 dB at one meter from front panel

H: 1194H: 1397 (top of exhaust)W: 724D: 1765

Net: 968.4kgShip: 991.6kg*Additional: 75kg when fuel tank is full

Paralleled(Combined)

40 – 800 a

700 a at 44 V, 100% Duty Cycle800 a at 38 V, 100% Duty Cycle

CV/DC (MIG/FCaW)

Separate(Dual Outputs)

14 – 40 V

400 a at 34 V, 100% Duty Cycle (Each Side)

Paralleled(Combined)

14 – 40 V

750 a at 40 V, 100% Duty Cycle800 a at 38 V, 100% Duty Cycle


34 CONTENTS


BOB, NO 1 FABRICATOR TRIPLE EIGHT RACE ENGINEERING



35 CONTENTS

Arc & TIG

PRODUCT PROCESS

CAC-A WELDABLE MATERIALS

WELDING AMPERAGE RANGE

INPUT VOLTAGE

GENERATOR POWER REQUIRED


Maxstar 150 STH

N/a Steel, Stainless

5 - 150 DC 115/240 V

*6.5 kVa Sheet Metal,

Marine, Site Welding, Maintenance

Maxstar 200DX

N/a Steel, Stainless

1 - 200 DC 115/240/415 V

*7 kVa Sheet Metal,

Marine, Site Welding, Maintenance

Maxstar 280DX

3/16” (4.8mm)

Steel, Stainless

5 - 280 DC 115/240/415 V

*12.5 kVa Sheet Metal,

Marine, Site Welding, Construction, Maintenance

Dynasty 200DX

N/a Steel, aluminium, Stainless

5 - 200 aC 1 - 200 DC

115/240/415 V

* 11 kVa

Sheet Metal, Marine, Site Welding, Maintenance

Dynasty 280DX

3/16” (4.8mm)

Steel, aluminium, Stainless

5 - 280 aC/DC

115/240/415 V *

12.5 kVa Sheet Metal, Marine, Site Welding, Maintenance

Dynasty 350DX

1/4” (6mm)


3 - 350 aC/DC

415 V 16.5 kVa Sheet Metal, Marine, Maintenance

STI

CK

AC

TIG

DC

TIG

HIG

H F

REQ

LIFT

AR

C

PU

LSE

LOW

OC

V

Capability Designed for this process * autoline

ARC & TIG


36 CONTENTS

Maxstar 150 STHPart No: MR907352-1

LIGHTWEIGHT & PORTABLE DC OUTPUT TIG/STICK MACHINE.

ARC & TIG

AUTO-LINE™ POWER MANAGEMENTautomatically compensates for various input Voltage. Suits jobsite and generator power.

LIGHTWEIGHT & PORTABLEEasy to move around the workshop or jobsite – only 6.2kg.

BUILT-IN PULSING CAPABILITIESallows the operator to select from four fixed pulse frequencies to satisfy the application.

SELECTABLE TRIGGER CONFIGURATION The operator can choose standard or 2T trigger method to meet the application.

LIFT-ARC™ STARTINGProvides TIG arc starting without the use of high frequency.

HF STARTNon-contact arc starting to eliminate tungsten or material contamination.

BUILT-IN GAS SOLENOIDEliminates the need for a bulky torch with a gas valve.

ADAPTIVE HOT START™ automatically increases the output amperage at the start of a weld should the start require it. Prevents the electrode from sticking and creating an inclusion.

LOW OCV STICKReduces the open-circuit Voltage to 12–16 Volts when the welding power source is not in use. In accordance with CaT C aS 1674.2. (Nb: does not have a VRD indicator).

THERMAL OVERLOAD PROTECTION Helps prevent machine damage if the duty cycle is exceeded or airflow is blocked.

FAN-ON-DEMAND™

Power source cooling system operates only when needed - reducing noise, energy use and the amount of contaminants pulled through the machine.

3 YEAR WARRANTYFor details, refer to Miller's True Blue warranty statement.

INPUT POWER

WELDING AMP RANGE

RATED OUTPUT AMPS INPUT AT RATED OUTPUT 50/60 HZ

KVA AT DUTY CYCLE

DIMENSIONS (MM)

WEIGHT

230 VaC Stick

20 - 150 a 100 a at 24.0 VCD, 100% Duty Cycle 13.1 3.0 H: 229W: 140D: 337

6.2kg

150 a at 26.0 VCD, 30% Duty Cycle 21.6 4.9

230 VaC TIG 5 - 150 a



APPLICATIONS

Process PipeDairy IndustryFood/Beverage IndustryShipboard Installation/RepairMaintenance Repair

PROCESSES

TIG (GTaW)Pulsed TIG (GTaW-P)Stick (SMaW)

37 CONTENTS

Maxstar 200DXPart No: MR907354

FOR JOBS THAT DEMAND PRECISION.

ARC & TIG

AUTO-LINE™ POWER MANAGEMENTautomatically compensates for various input Voltage. Suits jobsite and generator power. Single or 3 phase.

FAN-ON-DEMAND™


LIFT-ARC™ STARTINGProvides X-Ray clean welds without the use of high frequency.

BLUE LIGHTNING™

High-frequency arc starter for non-contact arc initiation. Provides more consistent arc starts and greater reliability compared to traditional HF arc starters. Easy to set and increases productivity.

DC TIG FEATURESExceptionally smooth and precise arc for welding exotic materials.

STICK FEATURES (DC)Tailored arc control (DIG) allows the arc characteristic to be changed for specific applications and electrodes. Smooth running 7018 or stiffer, more penetrating 6010.

HOT-START™

Provides positive arc starts without sticking.

LOW OCV

VRD TO CAT C AS 1674.2


WELDING MODE

RATED OUTPUT AMPS INPUT AT RATED OUTPUT, 50/60 HZ

DIMENSIONS (MM)

WEIGHT

230 V 1 PHASE

400 V 3 PHASE

KVA

TIG (GTaW) 175 a at 17 V, 60% Duty Cycle 17.4 6.0 a 4.2 H: 343W: 191D: 445

16.8kg

Stick (SMaW) 150 a at 26 V, 60% Duty Cycle 21.7 7.4 a 5.2


Precision FabricationPetro ChemicalFood & Beverage Industry


38 CONTENTS

Maxstar 280DXPart No: MR907539002

ARC & TIG

UPGRADABLE & EXPANDABLEFront panel memory card data port provides the ability to easily upgrade software and expand product features.

PRO-SETEliminates the guesswork when setting weld parameters. Use Pro-Set when you want the speed, convenience and confidence of preset controls. Simply select the feature and adjust until Pro-Set appears on the display.

SLEEP TIMERConserves electricity. This programmable feature will power down the machine if it sits idle for a specific time.

BLUE LIGHTNING™High-frequency (HF) arc starter for non-contact arc initiation.

METER CALIBRATIONallows digital meters to be calibrated for certification.

WIND TUNNEL TECHNOLOGY™Protects internal electrical components from airborne contaminates, extending the product life.

COOL POWER SUPPLYIntegrated 120-volt dedicated-use receptacle to power the Coolmate™ 1.3. The power switch on the Maxstar also activates the receptacle to help prevent torch failure.

FAN-ON-DEMAND™Power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled though the machine.

DC TIG FEATURES Pulse. Pulsing can

increase puddle agitation, arc stability and travel speeds while reducing heat input and distortion. DX models provide extended ranges. Exceptionally smooth

and precise arc for welding exotic materials.

DC STICK FEATURES DIG allows the arc

characteristics to be changed for specific applications and electrodes. Lower the DIG setting for

smooth running electrodes like E7018 and increase the DIG setting for stiffer, more penetrating electrodes like E6010. Hot Start™ adaptive

control provides positive arc starts without sticking. Stick-Stuck detects if the

electrode is stuck to the part and turns the welding output off to safely and easily remove the electrode. Menu selectable.

3 YEAR WARRANTYFor details, refer to Miller’s True Blue warranty statement.

APPLICATIONS

Precision FabricationPetro ChemicalaerospaceFood/Beverage IndustryDairyShipboard

PROCESSES

DC TIG (GTaW)Pulsed TIG (GTaW-P)Stick (SMaW)

WELDING MODE


DIMENSIONS (MM)

WEIGHT

230 V 1 PHASE

400 V 3 PHASE

KVA

TIG (GTaW) 235 a at 19.4 V, 60% Duty Cycle 26 a 9 a 12.5 H: 346W: 219D: 269

22.7kg

Stick (SMaW) 235 a at 19.4 V, 60% Duty Cycle 27 a 10 a 12.5

NEW PRODUCT AVAILABLE SEPTEMBER 2014

39 CONTENTS

Dynasty 200DXPart No: MR907356

IDEAL FOR MAINTENANCE JOBS SPLIT BETWEEN THE WORKSHOP & SITE.AUTO-LINE™ POWER MANAGEMENTautomatically compensates for various input Voltage. Suits jobsite and generator power.

FAN-ON-DEMAND™



WELDING MODE

AMP RANGE RATED OUTPUT AMPS INPUT AT RATED OUTPUT, 50/60 HZ

DIMENSIONS (MM)

WEIGHT

230 V 1 PHASE

400 V 3 PHASE

KVA

TIG (GTaW) aC 5 - 150 a DC 1 - 150 a (115 VaC)


33 a 9 a 5.5 H: 343W: 191D: 546

20.5kg


15.8 a 6 a 3.8

Stick (SMaW) aC 5 - 105 a DC 1 - 105 a

200 a at 28 V, 20% Duty Cycle 33 a 13 a 8.1

BLUE LIGHTNING™

High-frequency arc starter for non-contact arc initiation. Provides more consistent arc starts and greater reliability.

WIND TUNNEL TECHNOLOGY™

Protects internal components from airborne contaminates, extending product life.



* Dependent on load variables, full output may not be available at 240 V 1 phase.


Precision FabricationPetro ChemicalFood & Beverage IndustryDairyShipboard


ARC & TIG

40 CONTENTS


ARC & TIG

APPLICATIONS

Precision FabricationHeavy FabricationPipe and Tube Fabricationaerospacealuminum Ship Repairanodized aluminum Fabrication

PROCESSES

aC/DC TIG (GTaW)Pulsed TIG (GTaW-P)Stick (SMaW)

WELDING MODE


DIMENSIONS (MM)

WEIGHT

230 V 1 PHASE

400 V 3 PHASE

KVA

TIG (GTaW) 235 a at 19.4 V, 60% Duty Cycle 30 a 10 a 12.5 H: 346W: 219D: 269

25kg

Stick (SMaW) 235 a at 19.4 V, 60% Duty Cycle 31 a 11 a 12.5

UPGRADABLE & EXPANDABLEFront panel memory card data port provides the ability to easily upgrade software and expand product features.

PRO-SETEliminates the guesswork when setting weld parameters. Use Pro-Set when you want the speed, convenience and confidence of preset controls. Simply select the feature and adjust until Pro-Set appears on the display.

SLEEP TIMERConserves electricity. This programmable feature will power down the machine if it sits idle for a specific time.

BLUE LIGHTNING™High-frequency (HF) arc starter for non-contact arc initiation. Provides more consistent arc starts and greater reliability compared to traditional HF arc starters.

WIND TUNNEL TECHNOLOGY™Protects internal electrical components from airborne contaminates, extending the product life.

METER CALIBRATIONallows digital meters to be calibrated for certification.

COOL POWER SUPPLYIntegrated 120-volt dedicated-use receptacle to power the Coolmate™ 1.3. The power switch on the Maxstar also activates the receptacle to help prevent torch failure.

FAN-ON-DEMAND™Power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled though the machine.

DC TIG FEATURES Exceptionally smooth

and precise arc for welding exotic materials.

AC TIG FEATURES Balance control provides

adjustable oxide removal which is essential for creating the highest qualityaluminum welds. DX models provide extended ranges. Frequency controls the

width of the arc cone and can improve directional control of the arc.

AC/DC STICK FEATURES Hot Start™ adaptive

control provides positive arc starts without sticking. aC frequency control adds

stability for smoother welds when aC Stick welding. Stick-Stuck detects if the

electrode is stuck to the part and turns the welding output off to safely and easily remove the electrode. Menu selectable.


NEW PRODUCT AVAILABLE SEPTEMBER 2014

41 CONTENTS


EXCEPTIONALLY SMOOTH & PRECISE ARC.

AMP RANGE RATED OUTPUT AMPS INPUT AT RATED OUTPUT, 50/60 HZ

DIMENSIONS (MM)

WEIGHT

400 V KVA

3 - 350 a 250 a at 30 V, 100% Duty Cycle 15 a 10.3 H: 629W: 349D: 559

61kg

300 a at 32 V, 60% Duty Cycle 18 a 12.7

FAN-ON-DEMAND™



BLUE LIGHTNING™

High-frequency arc starter for non-contact arc initiation. Provides more consistent arc starts and greater reliability.

METER CALIBRATIONallows meters to be calibrated for certification.


Protects internal electrical components from airborne contaminants, extending the product life.

PROGRAM MEMORYFeatures 9 independent program memories that maintain/save your parameters.

AUTO-POSTFLOW Calculates the length of

postflow time based on the amperage setting. This eliminates the need

to independently set the postflow time for different amperages. This feature preserves

your tungsten and prevents porosity.




Precision FabricationHeavy FabricationPipe and Tube Fabricationaluminium Ship Repairanodized aluminium Fabrication


ARC & TIG

42 CONTENTS

43 CONTENTS

MIG & Multi-ProcessPRODUCT PROCESS

CAC-A WELDABLE MATERIALS

WELDING OUTPUT RANGE

INPUT VOLTAGE

GENERATOR POWER REQUIRED


Deltaweld 602

5/16" (8 mm)


10 - 38 V CV

415 V 25 kVa Construction, Fabrication, Mining, Maintenance

XMT 350 Opt 1/4" (6 mm)


5 - 425 a CC 10 - 38 a CV

240/ 415 V

*

15 kVa Construction, Fabrication, Mining, Maintenance

XMT 350 MPa

1/4" (6 mm)


5 - 425 a CC 10 - 38 a CV

240/ 415 V

*

15 kVa Construction, Marine, Maintenance

XMT 450 Opt 3/8" (9.5 mm)


15 - 600 a CC 10 - 38 V CV


XMT 450 MPa

3/8” (9.5 mm)


15 - 600a CC 10 - 38 V CV


Dimension 562

5/16" (8 mm)


20 - 565 a CC 10 - 38 V CV


Dimension 812

Opt 3/8" (9.5 mm)


50 - 815 a CC 10 - 65 V CV


PipeWorx Welding System

Opt 3/8" (9.5 mm)

Steel, Stainless

40 - 350 a CC 10 - 44 V CV

415 V 20 kVa Pipeline, Pipe Spooling

PipeWorx 350 FieldPro™

1/4” (6.4 mm)

Steel, Stainless

10 - 350 a CC 10 - 44 V CV

240/ 415 V

15 kVa Pipeline, Pipe Spooling

STI

CK

DC

TIG

HIG

H F

REQ

LIFT

AR

C

MIG

FC PU

LSE

LOW

OC

V

Capability Designed for this process Capable of this process * autoline

MIG & MULTI-PROCESS

44 CONTENTS

Deltaweld 602Part No: MR907358

RATED OUTPUT

VOLTAGE RANGE

RECOMMENDED WELDING RANGE

INPUT AT RATED LOAD OUTPUT, 50/60Hz


DIMENSIONS (MM)

WEIGHT

400 V 3P

kVA kW

450 a at 38 VDC, 100% Duty Cycle

10 - 38 V 15 - 38 V 37 25.1 21.1 48 VDC H: 762W: 585D: 966

174kg

SUPERIOR ARC WELDING PERFORMANCE With MIG welding.

INTERNAL DIGITAL VOLTAGE CONTROL (DVC)Enables operator to preset weld Voltage before striking an arc.

LINE VOLTAGE COMPENSATIONEnsures consistent weld performance by keeping output power constant even if primary input power varies by ± 10%.

POWER EFFICIENTFor exceptional value and return on your investment.

THERMAL OVERLOAD PROTECTIONLight indicates power shutdown. Helps prevent machine damage if the duty cycle is exceeded or airflow is blocked.

DIGITAL VOLTMETER AND AMMETEREasy to read, even at 9.2m.

FAN ON DEMAND™

Operates only when needed reducing noise, power consumption, and the amount of airborne contaminants pulled though the machine.

14 PIN RECEPTACLEProvides quick, direct connection to Miller 14-pin wirefeeders and accessories.

REMOTE VOLTAGE CONTROLallows operator to change Voltage from wirefeeder.

ENCLOSED CIRCUIT BOARDSProvide additional protection from contaminants resulting in longer service life.

PC BOARD PROTECTIONPrevents the wirefeeder power or other stray Voltages (less than 115 VaC) from harming the power source PC board.


DC


Heavy Equipment ManufacturingShip and Boat BuildingTank/Pressure Vessel FabricationRailcar/Locomotive Fabrication and RepairStructural Steel FabricationSheet Metal Fabrication Maintenance

MIG (GMaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)Submerged arc (SaW)

MIG & MULTI-PROCESS

45 CONTENTS

XMT 350Part No: MR907161012

AUTO-LINE™ POWER MANAGEMENTautomatically compensates for various input Voltage. Suits jobsite and generator power. Keeps welding output constant even if input power varies by ±10%.

WIND TUNNEL TECHNOLOGY™ Protects electrical components and PC boards from contamination.

FAN-ON-DEMAND™ The cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through machine.

LIFT-ARC™ allows TIG starting without the use of high-frequency. Starts the arc without contaminating the weld with tungsten.

ADAPTIVE HOT START™

Increases the output amperage at the start of a weld if necessary, eliminating electrode sticking.

LIGHTWEIGHT, AEROSPACE-GRADE ALUMINIUM CASEOffers heavy-duty protection with the benefit of reduced weight.

INVERTER ARC CONTROL TECHNOLOGYProvides greater puddle control for superior 6010 Stick electrode performance, and outstanding MIG weld performance.

PROCESS SELECTOR SWITCHReduces the number of control setup combinations without reducing any features.

LARGE, DUAL DIGITAL METERSEasy to view and can be pre-set.

PULSED MIG (GMAW-P) CAPABILITIESWith optional Optima™ control reduces spatter and distortion, allows better out-of-position puddle control, and provides potential reduction of fume particle emission.

INPUT POWER

RATED OUTPUT

VOLTAGE RANGE - CV MODE

AMPERAGE RANGE IN CC MODE


DIMENSIONS (MM)

WEIGHT

230 V 1P

400 V kVA kW

3 Phase 350 a at 34 VDC, 60% Duty Cycle

10 - 38 V 15 - 425 a N/a 20.6 14.2 13.6 H: 432 W: 318D: 610

36.3kg

Single Phase 300 a at 32 VDC, 60% Duty Cycle 10 - 38 V 15 - 425 a 54.6 29.7 11.7 11.2



DCCCCV


ConstructionShipbuildingRailroadTruck/Trailer ManufacturingFabricationRepair ShopsRental FleetsPower Generation Plants

MIG (GMaW)Pulsed MIG (GMaW-P)Stick (SMaW)TIG (GTaW)Flux-Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)

MIG & MULTI-PROCESS

46 CONTENTS

XMT 350 MPaPart No: MR907366002

AUTO-LINE™ POWER MANAGEMENT automatically compensates for various input Voltage. Suits jobsite and generator power. Keeps welding output constant even if input power varies by ±10%. Single or 3 phase.

DINSE STYLE WELD DISCONNECTSProvides high-quality weld cable connections.










BUILT-IN PULSED MIG PROGRAMS WITH SYNERGIC CAPABILITY



INPUT POWER

RATED OUTPUT




DIMENSIONS (MM)

WEIGHT

230 V 1P

400 V 3P

kVA kW


10 - 38 V 15 - 425 a N/a 20.6 14.2 13.6 H: 432W: 318D: 610

36.3kg

Single Phase 300 a at 32 VDC, 60% Duty Cycle 10 - 38 V 15 - 425 a 54.6 29.7 11.7 11.2



MIG (GMaW)Pulsed MIG (GMaW-P)Stick (SMaW)TIG (GTaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)

MIG & MULTI-PROCESS

47 CONTENTS

XMT 450Part No: MR907525

INPUT POWER

RATED OUTPUT




DIMENSIONS (MM)

WEIGHT

400 V 3P

kVA kW


10 - 38 V 15 - 600 a 27.6 22 18.9 H: 438W: 368D: 689

55.3kg









LINE VOLTAGE COMPENSATIONKeeps welding output constant even if input power varies by ±10%. Line Voltage compensation further expands to an amazing +37/-59% when operating on 460 VaC.

PULSED MIG (GMAW-P) CAPABILITIESWith optional Optima™ control reduces spatter and distortion, allows better out-of-position puddle control, and provides potential reduction of fume particle emission.




MIG (GMaW)/Pulsed MIG (GMaW-P)Stick (SMaW)TIG (GTaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)

MIG & MULTI-PROCESS

EXCEPTIONALLY SMOOTH & PRECISE ARC.



48 CONTENTS

XMT 450 MPaPart No: MR907468

MIG & MULTI-PROCESS

INPUT POWER

RATED OUTPUT



MAX. OPEN- CIRCUIT VOLTAGE


DIMENSIONS (MM)

WEIGHT

400 V 3P

kVA kW


10 - 38 V 15 - 600 a 90 VDC 27.6 a 22 18.9 H: 438W: 368D: 689

55.3kg

DINSE STYLE WELD DISCONNECTSProvides high-quality weld cable connections.










BUILT-IN PULSED MIG PROGRAMS WITH SYNERGIC CAPABILITY





MIG (GMaW)Pulsed MIG (GMaW-P)Stick (SMaW)TIG (GTaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)

BEST IN CLASS OUTPUT POWER FOR THE TOUGHEST APPLICATIONS.

49 CONTENTS


WAYNE, LEAD WELDER ALFABS GROUP


http://welding.com.au/weldersofoz

50 CONTENTS

Dimension 562Part No: MR907360

ENGINEERED TO DELIVER EXCEPTIONAL PERFORMANCE FOR A RANGE OF PROCESSES.DC MULTI-PROCESS CAPABILITYProvides versatility and outstanding arc performance in CV (MIG) and CC (Stick, TIG, CaC-a).

INTERNAL DIGITAL VOLTAGE CONTROL (DVC)Enables operator to pre-set weld Voltage in the CV mode prior to welding.

BUILT-IN ARC CONTROLallows the operator to get in tight without sticking the electrode. an electrode compensation circuit ensures consistent arc control performance regardless of the electrode size.

LINE VOLTAGE COMPENSATION Ensures consistent weld performance by keeping output power constant even if primary input power varies by ±10%.

REMOTE VOLTAGE CONTROLallows operator to change Voltage from feeder.

14-PIN RECEPTACLEProvides quick, direct connection to Miller 14-pin wirefeeders and accessories.

ENCLOSED CIRCUIT BOARDS Provides additional protection from contaminants resulting in longer service life.

PC BOARD PROTECTION Prevents the wire feeder power or other stray Voltages (less than 115 VaC) from harming the power source PC board.

FAN-ON-DEMAND™


RATED OUTPUT

AMP/VOLT RANGE INPUT AT RATED OUTPUT, 50/60 Hz

DIMENSIONS (MM)

WEIGHT

400 V 3P

kVA kW

450 a at 38 VDC, (36.5 VDC for CE Model) 100% Duty Cycle

20 - 565 a in CC mode 46 31.4 22 H: 762 including lift eyeW: 585D: 966 including strain relief

192kg

450 a at 38 VDC, (36.5 VDC for CE Model) 100% Duty Cycle

10 - 38 V in CV mode 51 35.3 22.3

HOT-START™ Easy to start difficult Stick electrodes such as E-6010 and E-7018.



Fabrication and ConstructionHeavy ManufacturingMaintenance/RepairPressure Tank/Vessel FabricationPipe WeldingShipbuildingRefineries and FoundriesRailcar ManufacturingEarth-Moving Equipment Manufacturing

MIG (GMaW)Stick (SMaW)TIG (GTaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)Submerged arc (SaW)

MIG & MULTI-PROCESS

51 CONTENTS

Dimension 812Part No: MR907361 Part No: MR907361-1 [with VRD]

RATED OUTPUT

AMP/VOLT RANGE INPUT AT RATED OUTPUT, 50/60 Hz

DIMENSIONS (MM)

WEIGHT

400 V 3P

kVA kW


50 - 815 a in CC mode 73 50 34.8 H: 762 including lift eyeW: 585D: 966 including strain relief

247kg

DC MULTI-PROCESS CAPABILITYProvides versatility and outstanding arc performance in CV (MIG) and CC (Stick, TIG, CaC-a).

INTERNAL DIGITAL VOLTAGE CONTROL (DVC)Enables operator to pre-set weld Voltage in the CV mode prior to welding.

BUILT-IN ARC CONTROLallows the operator to get in tight without sticking the electrode. an electrode compensation circuit ensures consistent arc control performance regardless of the electrode size.

HOT-START™ Easy to start difficult Stick electrodes such as E-6010 and E-7018.

FAN-ON-DEMAND™


LINE VOLTAGE COMPENSATION Ensures consistent weld performance by keeping output power constant even if primary input power varies by ±10%.

14-PIN RECEPTACLEProvides quick, direct connection to Miller 14-pin wirefeeders and accessories.

REMOTE VOLTAGE CONTROLallows operator to change Voltage from feeder.

ENCLOSED CIRCUIT BOARDS Provides additional protection from contaminants resulting in longer service life.

PC BOARD PROTECTIONPrevents the wire feeder power or other stray Voltages (less than 115 VaC) from harming the power source PC board.



Fabrication and ConstructionHeavy ManufacturingMaintenance/RepairPressure Tank/Vessel FabricationPipe WeldingShipbuildingRefineries and FoundriesRailcar ManufacturingEarth-Moving Equipment Manufacturing

MIG (GMaW)Stick (SMaW)TIG (GTaW)Flux Cored (FCaW)air Carbon arc Cutting and Gouging (CaC-a)Submerged arc (SaW)

MIG & MULTI-PROCESS

52 CONTENTS

PipeWorx Welding SystemPart No: MR907534

Designed & Optimised for Pipe Fabrication Shops.

SINGLE SYSTEM DESIGNOne machine designed to perform all your pipe welding needs.



MULTI-PROCESS MACHINE Weld processes

are optimised to deliver superior arc performance and stability specifically for root pass, fill and cap pipe welding. Includes conventional

Stick, DC TIG (Lift-arc or HF Start), Flux-Cored and MIG welding processes. advanced RMD®

and Pulsed MIG processes deliver superior quality welds, increase productivity, and reduce rework and training.

MIG & MULTI-PROCESS

53 CONTENTS

WELDING MODE

RATED OUTPUT

AMPERAGE VOLTAGE RANGE


kVA (400 V)

kW (400 V)

DIMENSIONS (MM)

WEIGHT

400 V 3P

CC: Stick 350 a at 36 VDC, 100% Duty Cycle

40 - 350 a 25.5 17.8 16.5 H: 711W: 495D: 806(Power Source Only)

102kg(Power Source Only)

CC: DC TIG 350 a at 24 VDC, 100% Duty Cycle

10 - 350 a 18.1 12.5 9.8

CV: MIG/Flux Cored


10 - 44 V 25.7 18.0 15.6

SIMPLE PROCESS SET-UP Clearly labelled controls

in easy-to-understand welder terminology. Requires just a few basic

steps to set up a new weld process, resulting in less training time and minimizing errors from incorrect setups. The front panel was

designed by welders for welders. Only backlit controls are adjustable to eliminate confusion. Memory feature stores

four programs for each selection: Stick, DC TIG, and MIG (left and right side of feeder). Beneficial when using multiple procedures, multiple process parameters or multiple welders and eliminates the need to remember parameters.

SINGLE OR DUAL WIREFEEDER AVAILABLEWith simple operator interface. Wirefeed speeds up to 780 IPM.

STREAMLINED SYSTEM Wind Tunnel Technology™

and Fan-On-Demand™ provide system protection in the dusty shop environment. Innovative cable and gun

storage manages clutter for a cleaner, organised weld-cell area. Cables remain connected to the power source and do not need to be switched for the different welding processes. all system components

have been selected to meet the needs of a pipe fabrication shop.

QUICK PROCESS CHANGEOVER No need to manually

switch polarity or cables and hoses between processes. Simply push a process selection button to choose a welding process. PipeWorx ‘Quick-Select’ technology automatically selects the welding process, the correct polarity, cable outputs and welding parameters. Quick process changeover

eliminates set-up time for switching cables and gas hoses. also, reduces the risk of weld reworks due to incorrect cable connection.


APPLICATIONS

Process PipingRefineryPetrochemicalPowerHVaC and Water Pipe

PROCESSES

Stick (SMaW)DC TIG (GTaW)MIG (GMaW)MIG RMD® (GMaW MSC)Pulsed MIG (GMaW-P)Flux Cored (FCaW)

54 CONTENTS

PipeWorx 350 FieldPro™

Part No: MR907633 PipeWorx 350 FieldPro™ Part No: MR301177 FieldPro™ Smart FeederPart No: MR301176 FieldPro™ Remote Part No: MR301228 FieldPro™ Feeder

MIG & MULTI-PROCESS

Best in Class Productivity.

COMPLETE REMOTE CONTROL The FieldPro™ Remote

provides all the same functionality of the PipeWorx 350 FieldPro™ hundreds of feet from the power source, including process changeover, and amperage adjustment with no special cables. Connect the FieldPro™

Remote in line with the electrode holder or TIG torch with standard welding cables and have complete remote control.

SUPERIOR ARC PERFORMANCE The optimized Stick

and TIG performance specifically meets the needs of open root pipe welding and helps reduce training time and increases quality. Starts maintain root

opening and prepared edge and stops limit arc marks outside of the heat-affected zone.

EASY TO USE The PipeWorx 350

FieldPro™ is streamlined and simplified to reduce setup time and potential weld defects. Push button process changeover eliminates the need for swapping cables. The robust design will

withstand harsh environments common in the field.

NEW PRODUCT

AUTO-LINE™ POWER MANAGEMENT automatically compensates for various input Voltage. Suits jobsite and generator power. Keeps welding output constant even if input power varies by ±10%. Single or 3 phase.

55 CONTENTS

COMPLETE CONTROL AT THE WELD JOINT FieldPro™ Remote reduces

weld defects by automatically setting correct polarity for each welding process — without the need to manually swap cables. Eliminates the need to

“get by” with less than optimal settings without control cables, and allows for easy setup of a new weld process with the touch of a button. Total remote control of

welding processes and parameters improves safety by limiting jobsite movement and reducing slip, trip and fall hazards.

SIMPLIFIED CABLE MANAGEMENT Save time by eliminating

the need to trace cables back to change welding parameters and processes. No control cables to string

and manage on the jobsite.

ARC PERFORMANCE OPTIMISED FOR CRITICAL PIPE WELDING Industry-leading arc

performance like the PipeWorx 400 Welding System, but in a field-ready package. True multi-process

system provides conventional Stick, TIG, FCaW, and MIG welding as well as the advanced technologies of RMD and Pulse. Smart Feeder delivers

excellent RMD and Pulse welding up to 60 metres away from the power source with no control cables. RMD and Pulse processes

also help reduce weld failures and eliminate backing gas on some stainless and chrome-moly applications.



INPUT POWER

RATED OUTPUT

VOLTAGE RANGE IN CV MODE



RMS INPUT AT RATED LOAD OUTPUT, 50/60 Hz, 3-PHASE AT NEMALOAD VOLTAGES & CLASS 1 RATING

kVA kW DIMENSIONS (MM)

WEIGHT

230 V 1P

460 V 575 V

3 Phase


10 - 44 V 10 - 350 a 75 VDC 36.1 17.8 14.1 15.0 14.4 H: 432W: 305D: 559

43.1kg

1 Phase


54.6 25.4 19.9 11.7 11.2


Process PipingRefineryPetrochemicalPowerHVaC and Water Pipe

Stick (SMaW)DC TIG (GTaW)MIG (GMaW)MIG RMD® (GMaW MSC)Pulsed MIG (GMaW-P)Flux Cored (FCaW)air Carbon arc (CaC-a) Cutting and Gouging

FIELDPRO REMOTE

1. Stick Process Selection Button

2. Digital Meter

3. TIG Process Selection Button

4. amperage Output adjustment

5. In Use Indicator

6. Remote Indicators

7. In Use Indicator

8. Stick Electrode Type Selection

1

STICK TIG

IN USE

2

3

4

5

8 7 6

EXX10

EXX18

CHECK POLaRITY

aMPS

ELECTRODE

DCEN (-) STICK NEG

FIELDPRO aCCESSORY

14 PIN REMOTE

8 8 8

56 CONTENTS

57 CONTENTS

PLASMA CUTTING

Plasma Cutting

EXTREME RELIABILITY.

58 CONTENTS

Spectrum® 700iPart No: MR907543

Portable & Powerful 40 Amp Plasma Cutting Package.

HIGH PERFORMANCE COOLING SYSTEM WITH FAN-ON-DEMAND™

Thermal management system features new high-speed fan which only operates when torch trigger is engaged for improved reliability.


Prevents abrasive dust and particles from damaging internal components.

AUTOMATIC CONSUMABLE PROTECTIONDetects consumable type installed and adjusts gas pressure to optimise cutting performance, eliminating the need for a manual regulator.

AUTO-REFIRE™ TECHNOLOGYautomatically controls the pilot arc when cutting expanded metal or multiple pieces of metal. The pilot arc will switch in and out as fast as needed when cutting expanded metal and provides maximum power for cutting thicker metal - all automatically! No need for manual re-triggering, which reduces user hand fatigue.

AUTO POSTFLOWCalculates the length of postflow time based on the amount of cutting time to optimise consumable life and eliminate excessive air usage.

AUTOMATIC AIR REGULATIONThe unit automatically compensates for input pressure variation to provide constant recommended torch pressure for optimum cutting performance.

PLASMA CUTTING

59 CONTENTS

XT40 TORCHWith ergonomic handle to help prevent operator fatigue while the flexible cable makes manoeuvring easier.

LVC™ LINE VOLTAGE COMPENSATIONProvides peak performance power under variable conditions (power fluctuations up to ±15%) to deliver steady and cleaner ending cuts.

LED INDICATORFor pressure, power, cup and temperature. allows faster troubleshooting, eliminating unnecessary downtime.

CABLE MANAGEMENT STRAPSecures torch, work cable and power cord to make transporting easy and convenient.


MILD STEEL CUTTING CAPABILITY

CUTTING AT 40 AMPS (240 V)

1/4 IN. (6.4MM) AT 64 IPM

5/8 IN. (15.9MM) AT 13 IPM

THICKNESS APPROX. TRAVEL SPEEDS*

1/8 in. (3.2mm) 156 IPM (3963mm/min)

1/4 in. (6.4mm) 64 IPM (1626mm/min)

3/8 in. (9.5mm) 36 IPM (915mm/min)

1/2 in. (12.7mm) 22 IPM (559mm/min)

5/8 in. (15.9mm) 13 IPM (330mm/min)

*Travel speeds are approximately 80% of maximum.

NOTE: Recommended maximum piercing capacity for hand held application is 5/16 inches (7.9mm). Maximum sever cut of 7/8 inches (22.2mm) at approximately 5 IPM. For aluminium and other metals with high thermal conductivity, cutting capabilities will be derated as much as 30%.

Mild steel recommended cut speeds at 40 amps

PACKAGE INCLUDES: XT40 hand-held torch

with 3.7m flexible cable. Work clamp with

5.1m cable. 3m power cord. Extra consumables.

MILD STEEL CUTTING CAPACITY

INPUT POWER

RATED OUTPUT

AMPS INPUT AT RATED OUTPUT, 56/60 HZ

KVA KW DIMENSIONS (MM)

WEIGHT

Rated: 15.9mmSever: 22.2mm

240 V 40 a at 140 VDC, 50% Duty Cycle

28.5 aIeff = 20.2 a

6.6 6.5 H: 286W: 210D: 362

Net: 13.2kgShipping: 15.5kg

APPLICATIONS

MaintenanceLight ConstructionSheet Metal ShopsBody ShopsFabrication

RATED

15 amp plug supplied for commissioning purposes only.

60 CONTENTS

61 CONTENTS

Induction Heating

APPLICATIONS THAT WOULD TYPICALLY REQUIRE HOURS TO HEAT CAN BE DONE IN MINUTES WITH INDUCTION HEATING.

INDUCTION HEATING

62 CONTENTS

INDUCTION HEATING

Pro-Heat™ 35Part No: MR907432

MULTIPLE OUTPUTSProvides two insulated connectors for air- cooled blankets or liquid-cooled cables.

LOW CONSUMABLE COSTSNo fuel costs and minimal insulation costs. Insulation is reusable and may be used 50 times or more, reducing cost of disposal and replacement.

ON-BOARD TEMPERATURE CONTROLProvides for manual or temperature-based programming in a simple- to-learn operator interface.

MULTIPLE CONTROL THERMOCOUPLE INPUTS Control on the hottest TC during heating and coolest TC during cooling for uniform heating and quality.

OPEN OUTPUT DETECTIONPrevents system operation without a covered output receptacle (cable or protective plug).

Weld Pre-Heating & Stress Relieving.

*Image shows Water Cooled set up example.

63 CONTENTS

CABLE IDENTIFICATION SYSTEMKnows the type of cable attached and limits output to protect cables and blankets.

ISOLATION FAULT PROTECTION Provides automatic system shut down should power source output short to ground. a sense lead provides direct feedback to the power source to sense fault condition.

TIME-TO-TEMPERATUREFaster than conventional processes due to the method of applying the heat, reducing heating cycle time.

UNIFORM HEATINGHeating is maintained along and through the heat zone by using induction to heat within the material. The surface of the part is not marred by localized conducted heat at higher than specified temperatures.

IMPROVED AND SAFER WORKING ENVIRONMENTWelders are not exposed to open flame, explosive gases and hot elements associated with fuel gas heating and resistance heating.

AIR-COOLED INDUCTION HEATING SYSTEMDesigned for preheating applications up to 204°C.

APPLICATIONS

Transmission Pipeline – Construction/RepairPipe Fabrication ShopsPower Piping – Construction/RepairPetrochemical – Construction/RepairShipbuildingMining Equipment MaintenanceDrill Pipe ManufacturingShrink Fit

INPUT POWER

OUTPUT FREQUENCY

RATED OUTPUT

INPUT AMPS AT RATED OUTPUT

KVA/KW AT RATED OUTPUT

DIMENSIONS (MM)

WEIGHT

400 - 460 V, 3 Phase 50/60 Hz CE

5 - 30 kHz 35 kW at 100% Duty Cycle

60 a, 400 V 39/37 H: 669W: 552D: 933

103kg

LIQUID COOLED INDUCTION HEATING SYSTEMDesigned for preheating, hydrogen bake-out and stress relieving applications up to 788°C.

EASY SET-UP achieved using preheat blankets or flexible heating cables combined with user-friendly insulation blankets. Easy to install primary power through panel that does not require removal of sheet metal.


REDUCE PREHEATING TIME BY UP TO 400%Miller’s Induction Heating system brings a part to temperature in a fraction of the time, compared to traditional flame and resistance heating processes. It also holds the part at the specified temperature.

With Miller's Pro-Heat™, pre-heat time can be reduced by up to 400%. To put this in perspective, companies using the Pro-Heat™ have reduced pre-heating time from over two hours to just 30 minutes.

64 CONTENTS

Wirefeeders

PRODUCT PROCESS

WIRE SIZE SOLID

WIRE SIZE FLUX CORED


Weldmatic W64

CV 0.6 - 1.6mm 0.8 - 1.6mm Construction, Fabrication,Mining, Maintenance

Suitcase X-Treme 12VS

CC/CV

0.6 - 1.6mm 0.9 - 2.0mm Construction, Fabrication, Mining, Maintenance

Suitcase 12RC

CV 0.6 - 1.6mm 0.9 - 2.0mm Construction, Fabrication, Mining, Maintenance

22a CV * 0.6 - 1.6mm 0.9 - 2.0mm Construction, Fabrication, Mining, Maintenance

24a CV 0.6 - 1.6mm 0.9 - 2.4mm Construction, Fabrication, Mining, Maintenance

70 Series CV * 0.9 - 1.6mm 1.2 - 2.8mm Construction, Fabrication, Mining, Maintenance

70 Series MPa

CV 0.9 - 1.6mm 1.2 - 2.8mm Construction, Marine, Fabrication, Mining, Maintenance

MIG

MIG

PU

LSE

PO

RTA

BLE

PO

WER

REQ

SO

LID

WIR

E

FLU

X C

OR

ED

ALU

M

METE

RS

2 R

OLL

FEED

4 R

OLL

FEED

Capability Designed for this process Capable of this process * Optional

WIREFEEDERS

65 CONTENTS

WIREFEEDERS

Weldmatic W64 WirefeederPart No: W64-0

INCHallows wire to be fed without wasting gas.

LATCHProvides gun switch trigger to start and then again to stop, reducing operator fatigue on long welds.

PRE GASAllows gas to flow before weld starts.

POST GASAllows gas to continue flowing after weld has finished.

SPOT TIMEProvides short weld times for repetitive spot welds.

BURNBACKControls how far the wire burns back to the tip on completion of the welding operation.

4 ROLL DRIVE 50W MOTORProvides a consistent, strong drive for a variety of wires.

HEAVY DUTY 4 ROLL DRIVESystem has larger, stronger drive gears and ball bearings on drive rollers and shafts.

HIGH & LOW SPEED RANGEProvides 1 to 10m/min or 8 to 20m/min speed, giving finer control of wire speed – particularly useful at lower Voltage settings.

ARC START CONTROLallows starting response to be fine-tuned to weld conditions.

CREEP START MODEProvides slow wire speed until weld starts - ideal for aluminium starts.

PURGEallows gas line to be purged, without feeding wire.

4 ROLL DRIVE WIREFEEDER. SUITS WELDMATIC 270, 356, 396 & FABRICATOR.

SUPPLY VOLTAGE

RATED SUPPLY CURRENT

CIRCUIT BREAKER CURRENT

PRE-GAS RANGE

START SPEED SPOOL SIZES

WIRE SPEED RANGE

WIRE SIZE RANGE

32 Vac - (from welding source)

5 amps 5 amps 0 - 2 Seconds

Start or creep (switchable)

5kg, 15kg

0 - 10 metres per min low speed range8 - 20 metres per min high speed range

0.6mm - 1.6mm diameter

66 CONTENTS

Suitcase® X-Treme™ 12VSPart No: MR300876

SCALED WIRE PRESSURE KNOB Provides easy adjustment

and consistent pressure on the drive rolls and wire. The wire drive and motor

assembly is specifically designed for mobile welding applications to provide smooth and consistent wire delivery.

NEW WIRE DELIVERY SYSTEMBends wire over a large radius and applies just the right amount of force to ensure consistent feeding.

Taking Portable Welding to the Extreme!

ULTRA-LOW DRAG INLET GUIDE PINS Makes loading the wire

easy and does not deform the wire on the way into the drive rolls. Simply thread the wire through the pins and into drive rolls. There are two ways to

advance the wire through the drive roll and into the gun. Either open the pressure

arm and thread the wire into the grooves in the drive roll and on into the gun inlet or place the wire between the pins and use the jog/purge switch to advance the wire through the drive roll.

WIREFEEDERS

NEW RELEASE

67 CONTENTS

CONSISTENT WIREFEED Provides wire feed

speed that is accurate and consistent from the start of the weld to the finish, and from one weld to the next. Consistent wire feed speed

is very important with large-diameter cored wire, because small changes in wire feed speed make large changes in deposition rates.

EXCELLENT STARTSSuperior arc performance for all types and sizes of wires, whether using CV or CC power supply.

HIGHER DUTY CYCLELonger welding periods suitable for higher amperage applications due to the heavy duty contactor rated at 425 amps at 60%.

SUPERIOR LOW END PERFORMANCEExcellent arc performance and welding characteristics when welding at lower currents, either with small wire sizes or out of position applications.

QUICK SET-UP & REVIEWOperator friendly adjustments including easy to read digital amp & Volt meters.


ConstructionShipbuildingHeavy ManufacturingRental

MIG (GMaW)Flux Cored (FCaW)Pulsed MIG (GMaW-P)

OPERATOR CONVENIENCEPacked with features at your fingertips - including emergency isolation on/ off switch, trigger hold, gas purge and wire inch.

QUICK CHANGE ROLLERSNo tools required due to Miller’s patented quick lock hub system providing the operator quick and easy drive roller change when switching between wire sizes.

BUILT TO LAST IN HARSH ENVIRONMENTSThe plastic case design, potted PC board and double-filtered gas value ensure Suitcase withstands the harshest industrial environments.

WELDING MODE

INPUT WELDING CIRCUIT RATING

WIRE SPEED

ELECTRODE WIRE DIAMETER CAPACITY

MAX SPOOL SIZE CAPACITY

DIMENSIONS (MM)

WEIGHT

CC or CV/DC

425 a at 60% Duty Cycle

1.3 - 19.8 m/min

Solid Wire: 0.6 - 1.4mm Flux Cored: 0.8 - 2.0mm

305mm diameter up to 20kg

H: 394W: 229D: 533

15.9kg

IMPROVED WELD QUALITYWire drive with tachometer control improves weld feed speed accuracy and consistency to make it easier to produce quality welds.


68 CONTENTS

22A & 24APart No: MR300615

Suitcase 12RCPart No: MR300663004

WELDING MODE INPUT POWER WIRE SPEED

CV/DC 24 VaC, 10 a, 50/60 Hz

1.9 - 17.8m/min

ELECTRODE WIRE DIAMETER CAPACITY

DIMENSIONS (MM)

WEIGHT

Solid Wire: 0.6 - 1.6mm Flux Cored: 0.9 - 2.0mm

H: 394 W: 229 D: 533

11.6kg

MODEL INPUT POWER WIRE SPEED ELECTRODE WIRE DIAMETER CAPACITY

DIMENSIONS (MM)

WEIGHT

22a 24 VaC, 7 a, 50/60 Hz

75 –750 IPM (1.9 –19 m/min.)

.023 – 5/64 in. (0.6 – 2.0 mm) H: 279 W: 273D: 597

15.4kg

24a .023 – 3/32 in. (0.6 – 2.4 mm)

18kg

WIREFEEDERS

GEAR-DRIVEN DRIVE ROLLS Smooth, positive and accurate wire feed with long, uninterrupted service life. 24a has four drive rolls for larger wire diameters.

WIRE FEED SPEED RANGE 75 –750 IPM! This offers a wider operating range than the competition.

TRIGGER HOLD CONTROL allows operator to make long extended welds without having to hold gun trigger.

ON-BOARD BURN-BACK AND MOTOR RAMP CONTROL Offers unmatched starting and stopping performance on a variety of power sources. This helps to ensure positive arc starting performance.

16-GAUGE SHEET METAL HOUSING Robust in rough service applications and less prone to damage.

RUN-IN STANDARD ON 24AFor better arc-starting performance on a variety of wires.

REMOTE VOLTAGE CONTROL IS OPTIONAL ON 22A & 24AParameter adjustments can be made in weld cell or at a remote location.

69 CONTENTS

S MODELS (BASIC 70 SERIES FEEDERS) Wire speed control.

Factory-set run-in control for improved arc starts.

24 VDC high-torque, permanent-magnet motor.

Quick-release, drive-roll pressure adjustment arm allows drive roll change without losing spring preload setting.

Solid-state speed control and brake circuit for increased service life.

Floating positive drive systems provide trouble-free feeding on a variety of wires.

WIREFEEDERS

70 SeriesPart No: MR300616 [S-74S Standard]Part No: MR300617 [S-74D Digital] Part No: MR300618 [S-74DX Digital]*Part No: MR300620 [D-74D Digital Dual]*

WELDING MODE

INPUT POWER

WIRE SPEED ELECTRODE WIRE DIAMETER CAPACITY

DIMENSIONS (MM)

WEIGHT

CV/DC 24 VaC, 10 a, 50/60 Hz

1.3 - 19.8m/min Solid Wire: 0.9 - 1.6mm Flux Cored: 1.2 - 2.8mm

S-74 Single: H: 356 W: 318 D: 711D-74 Dual: H: 356 W: 533 D: 889

S-74 Single: 26kgS-74 D-74 Dual: 39.5kg

D MODELS ADD THE FOLLOWING FEATURES

Digital meters for easy viewing of the wire feed speed and Voltage.

Remote Voltage control allows operator to set Voltage at the wire feeder without having to go back to the power source.

Tachometer feedback to help keep wire feed speed accurate.

DX MODELS ADD THE FOLLOWING FEATURES

Four weld programs allow the operators to store four independent welding parameters reducing welding setup time (four programs available per side on dual feeder).

adjustable run-in control for improved arc starts.

adjustable weld sequence control gives operator complete control of the welding parameters: pre-flow, run-in, weld time, crater, burn-back and post-flow.

Welding process range control locks parameters at a set percentage of welding parameters to ensure welding procedures and quality standards are maintained on the shop floor.

Dual schedule allows operator to switch between two welding parameters without readjusting the machine, eliminating downtime and enhanching quality.

* Indent only

70 CONTENTS

74 MPa PlusPart No: MR300577

INPUT POWER

WIRE SPEED ELECTRODE WIRE DIAMETER CAPACITY

DIMENSIONS (MM)

WEIGHT

CV/DC 1.3 - 19.8m/min Solid Wire: 0.9 - 1.6mm Flux Cored: 1.2 - 2.8mm

H: 356 W: 533 D: 889 39.5kg

MPA PLUS WIREFEEDERS OFFER THE BENEFITS OF THE STANDARD S, D AND DX MODELS, PLUS EVEN MORE.

ALUMINATION™ TECHNOLOGY Alumination™ technology

gives you the ability to use the extended reach of a push-pull system for consistent, versatile and dependable aluminium wire feeding. Alumination™ gives

you the versatility to handle whatever aluminium welding job you want to tackle.

WIREFEEDERS

SYNERGIC PULSED MIG Synergic Pulsed MIG

operation when optimized with the XMT MPa power supplies. Provides communication

between the power source, feeder and gun. as wire speed increases/

decreases, the pulse parameters also increase/decrease to match the right amount of power needed.

TRIGGER SCHEDULE SELECT Trigger schedule select

allows the operator to select the alternative schedule by quickly tapping the gun trigger when not welding. When optimized with the

XMT MPa power supply the operator can also switch from MIG to Pulsed MIG.

PROFILE PULSE™ Profile Pulse™ provides

TIG appearance with MIG simplicity and productivity. achieve “stacked dime”

weld bead appearance without back-stepping. Profile Pulse™ frequency

can be changed to increase or decrease the spacing between the ripple pattern to achieve the desired weld appearance.

71 CONTENTS

72 CONTENTS

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73 CONTENTS

Filler MetalsWELDING ELECTRODES, WIRES & HARDFACING PRODUCTS.

http://www.welding.com.au/news/view/australian-welding-guide-available-to-download

74 CONTENTS

75 CONTENTS

Electrodes

HIGH PERFORMING WELDING ELECTRODES DESIGNED FOR THE NEEDS OF THE INDUSTRIAL USER.

76 CONTENTS

CLASSIFICATION: aS/NZS 4855-B – E43 13a aWS a5.1: E6013

DESCRIPTION: austarc 13S is a popular

blue and white striped mild steel general purpose electrode for welding in down hand and vertical up positions. It has a soft and stable arc

and produces flat, uniform fillet welds with ease and a self-peeling slag action. Easy to use for less

experienced operators.

GENERAL PURPOSE ELECTRODES - MILD STEEL

Austarc 12P

Austarc 13S

TYPICAL APPLICATIONS:Structural welding of sheet and plate steel (galvanised or otherwise) and tubular sections, including trailers, duct work, hoppers and storage tanks iron.

CLASSIFICATION: aS/NZS 4855-B – E43 13 a aWS a5.1: E6013

DESCRIPTION: a popular, easy starting,

smooth running, all positional mild steel general purpose electrode. austarc 12P has the extra

arc force and fast freezing slag required for vertical down welds.

With great operator appeal, it’s the ideal general purpose choice for the ‘one electrode’ workshop.

TYPICAL APPLICATIONS:Welding of general purpose structural steel, galvanised gates and fences, trailers, steel furniture and wrought iron.

TYPICAL ALL WELD METAL CHEMICAL ANALYSIS

C Mn Si P S Fe

0.07 0.52 0.32 0.013 0.006 Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS

Yield Stress 450 MPaTensile Strength 500 MPaElongation 26%CVN Impact Values 70J @ 0ºC

ORDERING INFORMATION

ELECTRODE SIZE (MM)

PACKAGING (KG) APPROX NO OF RODS PER KG

PART NUMBERPACKET CARTON

2.0 2.5 12.5 100 12P202.5 2.5 12.5 64 12P253.2 5.0 15 31 12P324.0 5.0 15 21 12P40FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)

2.0 & 2.5 9753.2 & 4.0 900

GENERAL PURPOSE ELECTRODES - MILD STEEL


C Mn Si P S Fe

0.07 0.48 0.41 0.016 0.005 Bal




ELECTRODE SIZE (MM)



2.0 2.5 12.5 99 13S202.5 2.5 12.5 64 13S253.2 5.0 15 31 13S324.0 5.0 15 20 13S40FULL PALLET QUANTITY


2.0 & 2.5 9753.2 & 4.0 900

STICK

STICK

77 CONTENTS

Austarc 16TC

HYDROGEN CONTROLLED ELECTRODES

DESCRIPTION: austarc 16TC is a smooth

running, low hydrogen electrode, developed for all positional welding, using aC or DC power sources. It has exceptional arc

stability and weldability and delivers high quality weld deposits with reliable notch toughness to -40 ºC. austarc 16TC is

manufactured using a unique twin coating extrusion process, which means all the arc stabilising elements are concentrated in the inner coating. This delivers significantly improved arc stability and control for all applications.

TYPICAL APPLICATIONS:

The ideal hydrogen controlled electrode for welding carbon, carbon-manganese and low alloy high strength steels used in a multitude of critical and non-critical applications. Typical applications

include pipe welding, single sided weld joints, highly restrained joints, maintenance applications, buffer layer prior to hard surfacing build-up, structural steel and sub-zero temperature applications.


C Mn Si P S Fe

0.05 1.16 0.42 0.013 0.006 Bal


Yield Stress 460 MPaTensile Strength 560 MPaElongation 28%CVN Impact Values 130J @ -20ºC & 110J @ -40ºC


ELECTRODE SIZE (MM)


PART NUMBER

PACKET CARTON

2.5 2.5 12.5 60 16TC253.2 5 15 29 16TC324.0 5 15 18 16TC405.0 5 15 10 16TC506.0 5 15 7 16TC60FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)2.5 9753.2 & 4.0 9005.0 & 6.0 810

STICK

CLASSIFICATION: aS/NZS 4855-B - E49 16 a U H10 aWS a5.1: E7016 H8

78 CONTENTS

DESCRIPTION: Smooth running basic

type iron powder electrode used for all positional welding except vertical down. This electrode is

used where the highest standards are required. Weld features include high ductility, x-ray quality and sub zero temperature impact to -50 ºC.

Austarc 18TC

Austarc 77

TYPICAL APPLICATIONS:For critical welding applications including repair and maintenance of heavy plate and highly restrained work pieces such as penstocks, turbines, pressure vessels, heavy girders, earth moving plants etc.



DESCRIPTION: austarc 18TC is an iron

powder hydrogen controlled electrode used primarily on C-Mn and low alloy structural steels. The unique twin-coat

design for 18 type low hydrogen electrode offers excellent aC arc stability and superb DC+ arc transfer, excellent re-strike,

reduced spatter level and extraordinary ease of use for out-of-position welding.

TYPICAL APPLICATIONS:Oil and gas, pipe welding, structural steel construction, off-shore where Ni-alloying is prohibited, mining equipment, heavy girders and earth moving plant repair and maintenance.


Yield Stress 530 MPaTensile Strength 602 MPaElongation 24%CVN Impact Values 87J @ -50 ºC


ELECTRODE SIZE (MM)



2.5 2.2 11 52 18TC253.2 5 15 26 18TC324.0 5 15 17 18TC40FULL PALLET QUANTITY


2.5 8583.2 & 4.0 900


C Mn Si S P Fe

0.06 1.55 0.54 0.020 0.010 Bal


Yield Stress 455 MPaTensile Strength 534 MPaElongation 30%CVN Impact Values 123J @ -50ºC


ELECTRODE SIZE (MM)



2.5 2.2 11 48 77253.2 5 15 25 77324.0 5 15 17 77405.0 5 15 9 7750FULL PALLET QUANTITY


2.5 8583.2 & 4.0 9005.0 810


C Mn Si P S Fe

0.06 1.40 0.36 0.015 0.006 Bal

STICK

CLASSIFICATION: aS/NZS 4855-B - E49 18-1 a U H5 aWS a5.1: E7018-1

CLASSIFICATION: aS/NZS 4855-B - E49 18-1 a U H5 aWS a5.1: E7018-1 H8

STICK

79 CONTENTS

DESCRIPTION: High cellulose electrode

developed for all positional welding on both aC and DC current. It is particularly suited for vertical and incline pipe welding where complete root penetration is required.

Austarc 11

TYPICAL APPLICATIONS:Recommended for pipeline welding and storage tank construction where either the ‘Stove Pipe’ or ‘Flick’ techniques can be used to obtain full-root penetration in critical structural joints.

Austarc 24

IRON POWDER ELECTRODES

CELLULOSE ELECTRODES

DESCRIPTION: Suited to long, heavy fillet

and butt welding using the touch welding or ‘short arc’ technique and can be used on aC or DC power sources. It’s instant arc initiation,

high arc stability, and low spatter combines in an excellent fillet weld contour, edge washing and slag

release. It is recommended for high quality down hand welding of heavy sections where high deposition rates are required.

TYPICAL APPLICATIONS:Tanks, structural frames, tractor, truck and trailer bodies, rolling stock, roof trusses etc.


C Mn Si P S Fe

0.05 0.99 0.42 0.017 0.011 Bal




ELECTRODE SIZE (MM)



3.2 5 15 17 24324.0 5 15 12 24405.0 5 15 6 2450FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)3.2 & 4.0 9005.0 810


C Mn Si P S Fe

0.12 0.82 0.20 0.012 0.008 Bal


Yield Stress 416 MPaTensile Strength 510 MPaElongation 32%CVN Impact Values 70J @ -30ºC


ELECTRODE SIZE (MM)



2.5 2.5 12.5 66 11253.2 5 15 33 11324.0 5 15 21 11405.0 5 15 14 1150FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)2.5 9753.2 & 4.0 9005.0 810

STICK

CLASSIFICATION: aS/NZS 4855-B - E49 24 a aWS a5.1: E7024

CLASSIFICATION: aS/NZS 4855-B - E43 11 a aWS a5.1: E6011

STICK

80 CONTENTS

DESCRIPTION: Staincord 316L-16 is

a Molybdenum bearing, 19Cr/12Ni/2.5Mo extra low carbon, rutile type electrode exhibiting superior all positional (except vertical down) performance with an improved moisture resistant “Pink” flux coating for weld metal of high radiographic integrity.

Staincord 309Mo-16

Staincord 316L-16

The smooth arc action of Staincord 316L-16, together with low spatter and excellent slag control/detachability, promotes exceptional weld appearance and profile. Other features include high arc stability and easy restriking on low Voltage aC welding machines.

TYPICAL APPLICATIONS:Recommended for welding 316, 316L and common 300 series stainless steels such as 301, 302, 304 and 304L. also suitable for welding ferritic stainless steel alloys such as 3Cr12.

STAINLESS STEEL ELECTRODES


DESCRIPTION: Staincord 309Mo-16 is a

Molybdenum bearing, highly alloyed 23Cr/12Ni/2.5Mo extra low carbon rutile type stainless steel electrode, exhibiting superior all positional (except vertical down) performance with an improved moisture resistant coating for weld metal of high radiographic integrity.

The smooth arc action of Staincord 309Mo-16, together with low spatter and excellent slag control/detachability, promotes exceptional weld appearance and profile.

TYPICAL APPLICATIONS:Suitable for welding of matching 309 and 309Mo base metals and a wide range of 300 and 400 series stainless steels to alloyed and non-alloyed dissimilar ferrous metal combinations.


C Cr Ni Mo Mn Si P S Cu

0.03 23.51 13.12 2.39 0.79 0.64 0.028 0.027 0.16


Yield Stress 400 MPaTensile Strength 670 MPaElongation 38%


ELECTRODE SIZE (MM)



2.5 2.5 12.5 56 SC309MO253.2 2.5 12.5 30 SC309MO32FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)2.5 & 3.2 900


ELECTRODE SIZE (MM)



2.0 2.5 12.5 84 SC316202.5 2.5 12.5 55 SC316253.2 2.5 12.5 28 SC31632FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)2.0, 2.5 & 3.2 900


Yield Stress 380 MPaTensile Strength 600 MPaElongation 40%


C Mn Si Cr Ni Mo Fe

0.02 0.74 0.71 17.97 12.48 2.37 Bal

STICK

STICK

CLASSIFICATION: aS/NZS 4854-B - ES309LMo-16 aWS a5.4: E309MoL-16

CLASSIFICATION: aS/NZS 4854-B - ES316L-16 aWS a5.4: E316L-16

81 CONTENTS

CLASSIFICATION: aWS a5.15: ENi-Cl

DESCRIPTION: Supercast Ni is a basic,

graphite coated aC/DC electrode for the lower strength welding of cast irons. It is characterised by a soft, smooth arc with low penetration and spatter levels on both aC and DC power sources. Ease of striking is a

feature of Supercast Ni and it also has a particularly good wetting action resulting in well bonded welds of regular contour and attractive appearance.

Supercast Ni

TYPICAL APPLICATIONS:For repair and build-up of all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of meehanite cast iron.

Unicord 312

CAST IRON ELECTRODES

DESCRIPTION: Unicord 312 is a basic,

rutile type electrode depositing a 29%Cr/9%Ni stainless steel weld metal for the high strength welding of a wide range of alloy steels and dissimilar ferrous metals. The high ferrite, austenitic

stainless steel deposit has excellent resistance to hot cracking, even under dilution by high carbon, alloy and

tool steels. Unicord 312 is a universal maintenance electrode combining high strength, toughness, wear and corrosion resistance with compatibility to most ferrous metals.

TYPICAL APPLICATIONS:For repair and maintenance of steels of unknown composition. also suitable as a buffer or intermediate layer prior to the application of hard surfacing.



Yield Stress 500 MPaTensile Strength 770 MPaElongation 45%Deposit Hardness 28-35 HRc


ELECTRODE SIZE (MM)



2.5 2.5 12.5 53 UC312253.2 2.5 12.5 27 UC31232FULL PALLET QUANTITY


2.5 & 3.2 900


C Cr Ni Mo Mn Si P S Cu

0.03 28.61 8.99 0.11 1.04 0.71 0.023 0.024 0.12


Yield Stress 200 MPaTensile Strength 400 MPaDeposit Hardness 150-170 HV (30)


ELECTRODE SIZE (MM)



3.2 2.5 12.5 33 SNI32FULL PALLET QUANTITY

ELECTRODE SIZE (MM) WEIGHT (KG)3.2 900


C Mn S Fe Ni

1.0 0.21 0.007 0.3 Bal

STICK

STICK

CLASSIFICATION: aS/NZS 4854-B - ES312-16 aWS a5.4: E312-16

82 CONTENTS

Supercast Ni/Fe

CLASSIFICATION: aWS a5.15: ENiFe-Cl

DESCRIPTION: Supercast Ni/Fe is a

basic, graphite coated aC/DC electrode for the higher strength welding of cast irons. It is characterised by

a soft, smooth arc with low penetration and spatter levels on both aC and DC power sources. Ease of striking is a

feature of Supercast Ni/Fe. This electrode is made

from a Nickel-Iron core wire and produces a ductile, machineable weld deposit with the extra strength required for welding SG (Spheroidal Graphite) irons.

TYPICAL APPLICATIONS:For repair and build-up of SG irons and all standard grades of grey cast iron, malleable iron, austenitic cast iron and some grades of meehanite cast iron. also suited to welding these cast irons to steel.

CAST IRON ELECTRODES


ELECTRODE SIZE (MM)



3.2 2.5 12.5 36 SNIFE32


Yield Stress 300 MPaTensile Strength 500 MPaDeposit Hardness 200-220 HV (30)


C Mn Ni S Fe

1.0 0.42 58.0 0.009 Bal

STICK

83 CONTENTS

Wires

HIGH PERFORMING WELDING WIRES DESIGNED FOR THE INDUSTRIAL USER.

84 CONTENTS

DESCRIPTION: Copper coated, all

positional low alloy wire used for welding medium to high strength steels, particularly where service temperatures up to 500̊ C are encountered.

Austmig ES6

Austmig ESD2

TYPICAL APPLICATIONS:Structural welding of sheet and plate steel (galvanised or otherwise) and tubular sections, including trailers, duct work, hoppers and storage tanks.

DESCRIPTION: Copper coated, low

carbon steel MIG wire specifically formulated for optimum performance under CO² and ar/CO² mixed gases.

TYPICAL APPLICATIONS:Suitable for welding mild and medium strength steels. Ideal for positional welding of sheet steel and steel pipes and tubes where the high silicon content promotes smooth even weld beads with excellent edge wetting and contour.

SOLID MIG WIRES - MILD STEEL


Gas Type CO² ar+18% CO²Yield Stress 462 Mpa 450 MpaTensile Strength 570 Mpa 560 MpaElongation 27% 27%CVN Impact Values 96J @ -30ºC 86J @ -30ºC


WIRE SIZE (MM)

PACKET SIZE AND TYPE

PART NUMBER

0.6 5kg Spool ES606M5KG15kg Spool ES606S



1.0 15kg Spool ES610S1.2 15kg Spool ES612S1.6 15kg Spool ES616SFULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG) 0.6, 0.8, 0.9, 1.0, 1.2 & 1.6 (15kg) 1,080


C Mn Si S P Fe

0.1 1.45 0.88 0.02 0.022 Bal

SOLID MIG WIRES - LOW ALLOY STEEL


Gas Type ar+18% CO² CO²Yield Stress 569 Mpa 562 MPaTensile Strength 662 Mpa 675 MPaElongation 25% 24%CVN Impact Values 57J @ -30ºC 81J @ - 30ºC


WIRE SIZE (MM)


PART NUMBER

0.9 15kg Spool ESD209S1.2 15kg Spool ESD212SFULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)0.9 & 1.2 1,080


C Mn Si Mo Fe

0.08 1.84 0.71 0.51 Bal

MIG

MIG

CLASSIFICATION: aS/NZS 14341-B - G 49a 3U C/M S6 aWS a5.18: ER70S-6

CLASSIFICATION: aS/NZS 14341 - B-G 55a 3U C/M G4M31 aWS a5.28: ER80S-D2

85 CONTENTS

DESCRIPTION: Precision layer wound

aluminium wire alloyed with Mg, Mn and Cr. Double shaved for superb feedability. The austmig 5183 can

achieve higher tensile strength in the as welded condition of alloy 5083, which the filler alloy 5356 will generally fail.

Austmig NiCrMo

Austmig 5183

TYPICAL APPLICATIONS:Recommended for welding 5083 type material in the annealed condition, particularly for low temperature applications where good ductility and toughness are required such as cryogenic plants and boat building.

DESCRIPTION: Copper coated, low alloy

solid wire suitable for all positional welding of high strength steels using ar/CO² mixed gases.

TYPICAL APPLICATIONS:Used for full strength welding of quenched and tempered structural steels of 760 MPa tensile class, such as USS-T1, Welten 80, N-a-XTRa and Bisplate 80.

SOLID MIG WIRES - ALUMINIUM

SOLID MIG WIRES - LOW ALLOY STEEL


Gas Type ar+18% CO²Yield Stress 770 MpaTensile Strength 880 MpaElongation 18%CVN Impact Values 68J @ -50 ºC


C Mn Si Ni Cr Mo V Fe

0.09 1.59 0.54 1.45 0.31 0.23 0.09 Bal


WIRE SIZE (MM)


PART NUMBER

0.9 15kg Spool MNICRM009S1.2 15kg Spool MNICRM012SFULL PALLET QUANTITY



WIRE SIZE (MM) PACKET SIZE AND TYPE PART NUMBER

1.2 6kg Spool M518312S1.6 6kg Spool M518316SFULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)1.2 & 1.6 504


Si Fe Cu Mn Mg Cr Zn Ti Al

0.4 0.4 0.1 0.5 - 1.0

4.3 - 5.2

0.05 - 0.25

0.25 0.15 Bal


Gas Type arYield Stress 110 MpaTensile Strength 240 MpaElongation 17%

MIG

MIG

CLASSIFICATION: aS/NZS ISO 18273 – S al 5183 aWS a5.10: ER5183

CLASSIFICATION: aS/NZS 16834-B - G 78a 5U M21 G aWS a5.28: ER110S-G

86 CONTENTS

DESCRIPTION: a metal-cored wire

designed for high speed fillet and butt welding in the down-hand position using argon + 18-25% CO² shielding gas mixtures. Weld beads are almost completely slag free with only minimal silicon islands, reducing the time and effort spent cleaning up prior to painting, coating or plating.

Austmig 5356

Austfil 70C-6M

TYPICAL APPLICATIONS:Recommended for single pass and multi pass welding in both the flat and horizontal positions for mild, carbon and manganese carbon steels with minimum clean up and where high deposition rates and efficiencies are required in high productivity, semi-automatic and fully automatic welding installations.

METAL-CORED GAS-SHIELDED WIRES

DESCRIPTION: Precision layer wound

al/5%Mg wire suitable for welding wrought or cast aluminium alloys containing magnesium as the major alloying element. The austmig 5356 is the

most widely used welding alloy filler metal, due to

its excellent corrosion resistance and high shear strength.

TYPICAL APPLICATIONS:Suitable for welding selected grades of wrought al/Mg alloys including 5083, 5086, 5454 and 5456.

SOLID MIG WIRES - ALUMINIUM


Zn Mg Mn Cr Si Fe Ti Al

0.1 5.2 0.15 0.1 0.25 0.4 0.15 Bal


Gas Type arYield Stress 125 MpaTensile Strength 275 MpaElongation 17%


WIRE SIZE (MM)


PART NUMBER

0.9 2kg Spool M5356092KG6kg Spool M535609S



1.6 6kg Spool M535616SFULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)0.9, 1.0, 1.2 & 1.6 504


WIRE SIZE (MM)


PART NUMBER

1.2 15kg Vacuum Packed Spool 70C6M12S1.6 15kg Vacuum Packed Spool 70C6M16S1.2 250kg Drum 70C6M12DFULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)1.2 & 1.6 (15kg) 1,0801.2 (250kg) 1,000


C Mn Si S P Cu Fe

0.05 1.62 0.58 0.006 0.012 0.03 Bal


Gas Type ar+25% CO²Yield Stress 569 MpaTensile Strength 634 MpaElongation 28%CVN Impact Values 62J @ -40ºC

MIG

MIG

CLASSIFICATION: aS/NZS ISO 18273 - S aI 5356 aWS a5.10: ER5356

CLASSIFICATION: aS/NZS IS0 17632-B - T494T15-0Ma-UH5 aWS a5.18: E70C-6M

87 CONTENTS

DESCRIPTION: all positional rutile

micro-alloyed type flux cored wire formulated for ar/CO² shielding gas mixtures (18-25% CO²). For optimum performance, argon with 25% CO² is recommended. Exceptionally smooth arc

performance producing a superb weld with low spatter losses in all positions with excellent operator appeal.

Austfil 71T-1M

TYPICAL APPLICATIONS: Recommended for the

welding of mild, carbon and carbon-manganese medium steels where good impact properties at -30˚C are required. Typical applications

include steel fabrication such as plate sections, beams, girders, truck chassis/bodies, ship building, earth moving equipment and storage tanks.

Austfil 71T

DESCRIPTION: A flux cored wire designed

for excellent performance in all positional fillet weld and butt-welding applications. It is formulated exclusively for use with cost effective CO² shielding gas.

TYPICAL APPLICATIONS: Recommended for

general purpose all positional welding of mild carbon and carbon-manganese steels where an excellent weld profile and penetration is required. Suitable for applications

such as storage tanks, structural fabrication, machinery, earth moving equipment and fatigue loaded structures.

FLUX-CORED GAS-SHIELDED WIRES



WIRE SIZE (MM)


PART NUMBER

1.2 15kg Spool 71T112S1.6 15kg Spool 71T116SFULL PALLET QUANTITY



Gas Type CO²Yield Stress 531 MpaTensile Strength 580 MpaElongation 26%CVN Impact Values 93J @ -20ºC


C Mn Si S P Fe

0.03 1.28 0.44 0.01 0.013 Bal

FC


WIRE SIZE (MM)


PART NUMBER

1.2 15kg Spool 71T1M12SFULL PALLET QUANTITY

WIRE SIZE (KG) WEIGHT (KG)1.2 1,080


C Mn Si S P B Fe

0.04 1.15 0.35 0.004 0.013 0.004 Bal


Gas Type ar+25% CO²Yield Stress 511 MpaTensile Strength 566 MpaElongation 32%CVN Impact Values 131J @ -30ºC, 108J @ -20ºC

FC

CLASSIFICATION: aS/NZS ISO 17632-B - T492T1-1 Ca-UH10 aWS a5.20: E71T-1 H8

CLASSIFICATION: aS/NZS ISO 17632-B - T493T1-1Ma-UH10 aWS a5.20: E71T-1M

88 CONTENTS

DESCRIPTION: Designed for mining and

earthmoving equipment and other fabrication where low temperature impact values are needed. The improved slag system

of this wire provides the superior welder appeal of acid slag (-T1) products and the mechanical properties normally associated with basic slag wires. Weld

Formula XL-525

FabCO 811N1

metal diffusible hydrogen levels are kept low, making this an excellent choice for the more demanding applications.

TYPICAL APPLICATIONS:High-strength low-alloy steels, bridge fabrication, structural fabrication, heavy equipment fabrication, shipbuilding, weathering steels when color-match is not required.

DESCRIPTION: A rutile flux cored all

position wire designed for welding mild and carbon steels, especially when good impact toughness is required at sub zero temperatures. Ideal for single and

multi-pass applications, it delivers outstanding welding performance and produces high quality X-ray clear weld deposit with a bead contour that is flat to slightly convex. It performs exeptionally well over rust,

mill scale and some primers with no pre-cleaning of the steel necessary. Formula XL-525 has

outstanding mechanical properties that resemble those of E7018 MMaW (SMaW) electrodes, plus high operator appeal with low fume levels, low spatter and easy slag removal.

TYPICAL APPLICATIONS:Recommended for ship building, storage vessels, off-shore structures, earth moving equipment and pipe welding.

FCFC


WIRE SIZE (MM)


PART NUMBER

1.2 15kg Spool S283212-0291.6 15kg Spool S283219-029FULL PALLET QUANTITY



Gas Type ar+20% CO²Yield Stress 503 MpaTensile Strength 566 MpaElongation 29%CVN Impact Values 90J @ -40ºC


C Mn Si Ni Fe

0.04 1.24 0.29 0.37 Bal

FCFC




Hydrogen Equipment 100% CO² 75% ar/25% CO²Gas Chromatography 2.4ml/100g 3.0ml/100g


Gas Type 100% CO² 75% ar/25% CO²Tensile Stress 572 Mpa 641 MpaYield Strength 503 Mpa 586 MpaElongation 27 23CVN Impact Values 88J @ -40ºC 54J @ -40ºC


C Mn P S Si Ni

100% CO² 0.03 1.09 0.007 0.005 0.32 1.0175% Ar/25% CO² 0.06 1.39 0.009 0.008 0.53 1.00


WIRE SIZE (MM)

PACKET SIZE AND TYPE PART NUMBER

1.2 15kg Vacuum Packed Spool S283612-0531.6 15kg Vacuum Packed Spool S283619-053FULL PALLET QUANTITY


CLASSIFICATION: aS/NZS IS0 17632-B - T494T1-1Ma-U H5 aS/NZS ISO 17632-B - T494T12-1Ma-U H5 aWS a5.20: E71T-1M, E71T-12MJ H8

CLASSIFICATION: aS/NZS ISO 17632-B - T554T1-1C/Ma-N2-UH5 aWS a5.29: E81T1-Ni1CJ H4, E81T1-Ni1MJ H4

89 CONTENTS

DESCRIPTION: Very high deposition

rate, self-shielding flux cored wire for down hand single or multi-pass welding applications. Specifically designed

to desulphurise the weld deposit to reduce risk of weld cracking.

FabCO 803

Fabshield 4

TYPICAL APPLICATIONS:Typical applications include on site field construction and repair of structural members and machinery.

DESCRIPTION: Offers excellent arc

stability and low spatter using either CO² or ar/CO² mixtures with up to 80% argon. These weldability

features, combined with low diffusible hydrogen levels and good impact values makes the wire a

good choice for single and multiple pass welding in all positions.

TYPICAL APPLICATIONS:applications include ship building, offshore drilling rigs, HSLa steels and weathering steels with no colour match requirement.

FCFC

FCFC


FLUX-CORED SELF-SHIELDED WIRES


WIRE SIZE (MM)


PART NUMBER

1.2 15kg Vacuum Packed Spool S283712-0531.6 15kg Vacuum Packed Spool S283719-053FULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (MM)1.2 & 1.6 1,080


SHIELDING GAS C Mn Si P S Ni

100% CO² 0.04 1.00 0.29 0.010 0.012 1.8475% ar/25% CO² 0.05 1.25 0.40 0.010 0.010 2.00


Gas Type 100% CO² 75% ar/25% CO²

Yield Stress 535 Mpa 598 Mpa

Tensile Strength 609 Mpa 660 Mpa

Elongation 27.5% 24%

CVN Impact Values 98J @ -40ºC 92J @ -51ºC

74J @ -40ºC 60J @ -51ºC


WIRE SIZE (MM)


PART NUMBER

2.4 22.7kg Coil S224529-0143.0 22.7kg Coil S224541-014FULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)2.4 & 3.0 726.4


C Mn Si P S Al Fe

0.27 0.73 0.30 0.011 0.005 1.42 Bal


Yield Stress 432 MPaTensile Strength 652 MPaElongation 25%CVN Impact Values Not Required

CLASSIFICATION: aS/NZS ISO 17632-B - T555T1-1C/Ma-N5-UH5 aWS a5.29: E81T1-Ni2C/MJ H4

CLASSIFICATION: aS/NZS ISO 17632-B - T49ZT4-0Na-H15 aWS a5.20: E70T-4

90 CONTENTS

DESCRIPTION: an all positional general

purpose, self-shielding, flux cored wire, designed specifically for single and multi-pass welding of mild steel and galvanised steel up to a maximum of 20mm in thickness.

Fabshield 21B

TYPICAL APPLICATIONS: For on-site welding

applications including farm and rural fabrication, fences, frames and sheds, etc. Other uses include

prefabricated steel frame construction, galvanised tank fabrication, repair of trucks, tractors and earth moving equipment.

FCFCFLUX-CORED SELF-SHIELDED WIRES


WIRE SIZE (MM)


PART NUMBER

0.8 4.5kg Spool S222106-0220.9 4.5kg Spool S222108-0220.9 15kg Spool S222108-0291.2 4.5kg Spool S222112-0221.2 15kg Spool S222112-0291.6 15kg Spool S222119-0292.0 15kg Spool S222125-029FULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)0.8, 0.9 & 1.2 (4.5kg) 8640.9, 1.2, 1.6 &2.0 (15kg) 1,080SHIPPING QUANTITY (KG)0.8, 0.9 (4.5kg) - 27 (6 spools)1.2 (4.5kg) -18 (4 spools)


C Mn Si S P Al Fe

0.28 0.34 0.15 0.008 0.003 1.72 Bal


Yield Stress 427 MPaTensile Strength 627 MPaElongation 22%CVN Impact Values Not Required

CLASSIFICATION: aS/NZS ISO 17632-B - T49ZT11-1Na-H15 aWS a5.20: E71T-11

91 CONTENTS

Fabshield XLR-8

DESCRIPTION: Low hydrogen T-8

self-shielded, all positional flux cored wire, producing a stable arc and flat bead profile, especially suited for vertical-up welds at high currents with excellent mechanical properties and a tensile strength of 490 MPa. Capable of depositing

X-ray quality welds, making it highly suitable for critical welding applications requiring a high degree of crack resistance due to its low diffusible hydrogen levels, less than 6.7ml per 100g of weld metal deposited. XLR-8 has been designed

for single and multi-pass welding applications with improved productivity in out-of-position welding, offering high impact strength of (42J) at sub zero temperatures to -40ºC.

TYPICAL APPLICATIONS:Specifically designed for increased productivity and high deposition rates on challenging structural steel erection, heavy equipment repair, mining equipment, bucket repairs, storage tanks, pipe spooling, ship construction and site work applications.

FCFC


C Mn Si P S Al Fe

0.19 0.51 0.17 0.009 0.006 0.51 Bal


Yield Stress 469 MpaTensile Strength 579 MpaElongation 28%CVN Impact Values 42J @ -40ºC, 54J@ -30ºC, 68J @ -20ºC


WIRE SIZE (MM)


PART NUMBER

1.6 15kg Vacuum Packed Spool S225719-0531.8 15kg Vacuum Packed Spool S225724-0532.0 15kg Vacuum Packed Spool S225725-0532.0 22.7kg Coil S225725-014FULL PALLET QUANTITY

WIRE SIZE (MM) WEIGHT (KG)1.6, 1.8 & 2.0 (15kg) 1,0802.0 (22.7kg) 726.4

CLASSIFICATION: aS/NZS IS0 17632-B - T494T8-1Na-H10 aWS a5.20: E71T-8JD H8

FLUX-CORED SELF-SHIELDED WIRES

92 CONTENTS

93 CONTENTS

Hardfacing Products

HIGH QUALITY HARDFACING ELECTRODES AND WIRES.

94 CONTENTS

CLASSIFICATION: aS/NZS 2576: 1435-a4

DESCRIPTION: Smooth running, aC/DC

electrode depositing a tough wear resistant air hardening C/Mn/Cr steel alloy which is machinable and can be readily hot forged. It offers high

compressive strength and excellent resistance to impact for all types of metal-to-metal wear.

Abrasocord 43

Abrasocord 350

TYPICAL APPLICATIONS:Suitable for the heavy build-up and surfacing of steel components subjected to metal-to-metal wear and compressive loading such as, track components, gears and shafts, etc.


DESCRIPTION: Heavy coated hardfacing

electrode depositing very hard Chromium/Niobium carbides in an austenitic matrix. It is ideal for hard

surfacing applications where resistance to extreme abrasion (in particular sliding abrasion) and moderate to heavy impact are required.

TYPICAL APPLICATIONS:Suitable for applications where resistance to extreme abrasion and moderate to heavy impact are required such as press screw, grizzly bars, crusher hammers, ripper teeth and shovel teeth.

HARDFACING ELECTRODES STICK


C Mn Cr Nb Fe

5.0 0.7 22.0 7.0 Bal


Single Layer onto Mild Steel Typical Hardness 60-65 HRcMulti-Layer Typical Hardness 64-69 HRc


ELECTRODE SIZE (MM)



3.2 5 15 16 aC43324.0 5 15 11 aC4340

STICK


C Mn Si Cr Fe

0.2 0.4 0.3 2.8 Bal




ELECTRODE SIZE (MM)



3.2 5 15 24 HF350324.0 5 15 16 HF35040

HARDFACING ELECTRODES

95 CONTENTS

CLASSIFICATION: aS/NZS 2576: 2355-a1*

* Nearest Classification

DESCRIPTION: Weld deposit offers

improved abrasion resistance through high levels of carbon and chromium. Ideal for hard surfacing

components subjected to heavy abrasion and moderate impact loading.

Abrasocord 700

Tubecord D-2355

TYPICAL APPLICATIONS:applications include hard surfacing of dredge bucket lips, shovel buckets, scraper and dozer sides, cone crushers and mill hammers, etc. Deposits are grindable, subject to relief checking and may be multi-layered up to 3 layers.


DESCRIPTION: Smooth running, aC/DC

electrode depositing an air hardening martensitic Cr/Mo/V steel alloy. It is one of the hardest

steel alloys available, is free from relief checks and offers good resistance to all types of abrasion under low to moderate impact conditions.

TYPICAL APPLICATIONS:Suitable for surfacing of post hole augers, agricultural points, shares and tynes, grader and cultivator blades and other components subject to fatigue or flexing during service.

HARDFACING ELECTRODES STICK

STICK




ELECTRODE SIZE (MM)



3.2 5 15 29 HF700324.0 5 15 18 HF700405.0 5 15 10 HF70050


C Mn Si Cr Mo V Fe

0.7 0.3 0.5 8.5 0.3 0.5 Bal


Single Layer Typical Hardness 55-60 HRc


ELECTRODE SIZE (MM)

PACKAGING (KG)PART NUMBERPACKET CARTON

6.3 5 15 TUBD60


C Cr Mn Fe

5.5 40.0 1.5 Bal


96 CONTENTS

CLASSIFICATION: aS/NZS 2576: 1855-B6

DESCRIPTION: a copper coated,

chromium alloy welding wire depositing weld metal with a hardness of 55-60 HRc which has a high resistance against severe abrasion and impact. The deposit is non-machineable but can be shaped by grinding. Recommended shielding

gas: argon/18-25/CO² or 100% CO².

Tubecord E-2460

Austmig TD-600

TYPICAL APPLICATIONS:applications include excavator blades, bucket lips, bucket teeth, screw conveyors, crushing mills and shear blades.


DESCRIPTION: Weld deposit contains

carbon, chromium, niobium and molybdenum for good resistance to both impact and abrasion.

TYPICAL APPLICATIONS:applications include hard surfacing of grizzly bars, bucket teeth, crusher hammers, rail ballast tampers, dredger and ripper teeth etc.

STICK


Singe Layer onto Mild Steel Typical Hardness 58-61 HRc


ELECTRODE SIZE (MM)

PACKAGING (KG)PART NUMBER

PACKET CARTON

6.3 5 15 TUBE608.0 5 15 TUBE80


C Cr Mo Nb V Mn Si Fe

4.0 26.5 0.9 7.9 0.4 0.8 1.5 Bal


HARDFACING SOLID MIG WIRES MIG


as Welded - Two Layers 55-60 HRc


ELECTRODE SIZE (MM)


PART NUMBER

1.2 15kg Spool MTD60012S


C Si Mn P S Cr Fe

0.45 0.40 0.36 0.018 0.002 9.30 Bal

97 CONTENTS


DESCRIPTION: a fabricated type, open

arc tubular flux cored wire depositing a Cr-Mo-W Martensitic steel alloy. It is designed for

surfacing mild and low alloy steel components subject to moderate abrasive wear and impact under high compressive stresses and/or at temperatures up to 530˚C.

Tube-Alloy 240-O

Tube-Alloy 258-O

Crack free deposits can be obtained by controlled heat input or the use of preheat.

TYPICAL APPLICATIONS:applications include machine components, tools and sliding metal to metal parts, dragline chains, kiln trunnions, mill guides, spindles and wobbler ends.


DESCRIPTION: Chromium carbide

surfacing alloy self-shielded hard surfacing wire which can be used on components subject to severe abrasive wear and heavy impact. Tougher than conventional chromium carbide.

TYPICAL APPLICATIONS:Applications include final overlays on roll crusher shells, final overlays on hammermill hammers, cone crushers, shovel teeth, augers and screw conveyors.

HARDFACING SELF-SHIELDED FLUX-CORED WIRES


HARDNESS

NUMBER OF LAYERS

AS DEPOSITED

1020 STEEL Mn STEEL

1 40 HRc 35 HRc2 48 HRc 42 HRc3-5 52 HRc 50 HRc

abrasion Resistance Very GoodImpact Resistance FairNon Machinable Grinding Is DifficultCannot Be Flame Cut Deposit Will Relief Check CrackThickness Should be Limited to Five Layers Maximum



1.2 11.3kg Coil S604012-029


C Mn Cr Nb Fe

3.20 1.80 1.90 15.50 Bal


HARDNESS

NUMBER OF LAYERS

AS DEPOSITED

1020 STEEL Mn STEEL

1 49 HRc 51 HRc2 53 HRc 54 HRc3-5 57 HRc 57 HRc

abrasion Resistance GoodImpact Resistance GoodNon Machinable Grinding OnlyFlame Cutting Difficult Heat Treatable and Forgettable Maintains Hot Hardness up to 530ºC



1.2 11.3kg Coil S605812-029


C Mn Si Cr Mo W Fe

0.45 1.40 0.80 6.00 1.50 1.50 Bal

HARDFACING SELF-SHIELDED FLUX-CORED WIRES FC

FC

98 CONTENTS

CLASSIFICATION: aS 2576: 1855-B5*

*Nearest Classification

DESCRIPTION: Gas shielded, all position,

hard surfacing flux cored wire depositing a multi-purpose martensitic steel alloy. Can be used to hard surface mild and low alloy steel components subject to moderate abrasion coupled with medium to high impact.

Tube-Alloy A43-O

Vertiwear 600

It also exhibits excellent compressive strength and metal to metal wear resistance. Excellent operator appeal in all positions. Recommended shielding

gas is 75% argon -25% CO².

TYPICAL APPLICATIONS:Typical applications include ripper teeth, dozer blades, dragline chains, facing of agricultural points and equipment, sliding metal parts and kiln trunnions.


DESCRIPTION: Self shielding wire

depositing a high Cr/Nb surfacing alloy which resists severe high and low stress abrasion and low to moderate impact. The weld deposit will

check crack readily and can be used where high temperature wear resistance is required.

TYPICAL APPLICATIONS:applications include augers, bucket lips and teeth, coal pulverizer rolls and tables, coke chutes, conveyor screws, dredge cutter heads and teeth, fan blades, grizzly and fingers, muller tires, paving agitator screws, pipeline ball joints, pub mill paddles, scraper blades, sheepsfoot tampers and sizing screws.


HARDNESS

NUMBER OF LAYERS

AS DEPOSITED

1020 STEEL Mn STEEL

1 56-60 HRc 45-50 HRc2 60-64 HRc 54-58 HRc

abrasion Resistance ExcellentImpact Resistance PoorNon Machinable Grinding OnlyCan Not Be Flame CutDeposit Will Relief Check CrackThickness 2-3 Layers Maximum


HARDNESS

NUMBER OF LAYERS

AS DEPOSITED

1020 STEEL

1 52 HRc2 56 HRc3 - 8 57 HRc

HARDNESS AS DEPOSITED

TIME AT TEMP

HARDNESS AFTER TEMPING

535°C 620°C

55 HRc10 Hours 54 HRc 46 HRc20 Hours 49 HRc 40 HRc80 Hours 47 HRc 40 HRc

abrasion Resistance: GoodImpact Resistance: GoodMachinability: GoodFlame Cutting: DifficultMagnetic



1.6 11.3kg Coil S607719-029


C Mn Si Cr Nb Fe

5.50 0.20 1.00 22.00 6.50 Bal

HARDFACING SELF-SHIELDED FLUX-CORED WIRES

HARDFACING GAS-SHIELDED FLUX-CORED WIRES



1.2 15kg Spool S607112-029


C Mn Si Cr Mo Fe

0.40 0.75 0.60 6.50 1.00 Bal

FC

FC

99 CONTENTS

Welding SafetyPROTECTION, PERFORMANCE & COMFORT.When it comes to welding safety equipment, it’s important to select a high quality welding helmet that is compliant with Australian Standards, to ensure protection of both the eyes and face during welding.

All WIA and Miller helmets have been tested to and comply with Australian and New Zealand standards - AS/NZS 1337.1 B (High Impact) and AS/NZ 1338.1 (Auto-Darkening).

When you select a WIA or Miller brand of Auto-Darkening helmet, you can be confident that you are using a high quality product that has undergone stringent testing to Australian and New Zealand standards.

100 CONTENTS

101 CONTENTS

WELDING SAFETY

MODEL SHADE ARC SENSORS

SWITCHING SPEED

VIEWING AREA

GRIND MODE

WARRANTY

WIa Blue 9-13 2 1/10,000 Sec

97 x 46mm

Yes 1 Year (auto- Darkening Lens Only)

Miller Performance™ 9-13 3 1/20,000 Sec

97 x 47mm

Yes 3 Years (auto- Darkening Lens Only)

Miller Digital Elite™ 9-13 4 independent sensors - plus X-Mode

1/20,000 Sec

97 x 60mm


Miller Titanium 9400™ 9-13 4 independent sensors - plus X-Mode

1/20,000 Sec

97 x 60mm


Miller Titanium 9400i™ 9-13 4 independent sensors - plus X-Mode

1/20,000 Sec

97 x 60mm


AUSTRALIAN STANDARDSaS/NZS 1338.1 (auto-Darkening)aS/NZS 1337.1 B (High Impact)

Auto-Darkening Helmet Selection Chart

102 CONTENTS

WELDING SAFETY

WIA Blue HelmetPart No: 235620

DESIGNED FOR THE WELDER WHO WANTS PROTECTION, PERFORMANCE & COMFORT AT AN AFFORDABLE PRICE.

AUSTRALIAN STANDARDS

AUSTRALIAN STANDARDSTested in australia, the lens and helmet comply with australian Standards aS/NZS 1338.1 (auto-Darkening) and aS/NZS 1337.1 B (High Impact).

VARIABLE SHADE CONTROLVariable control for adjustment of shade, lens sensitivity and delay for maximum control when welding. Shade 9-13.

CONVENIENT EXTERNAL SHADE CONTROLProvides flexibility to adjust shade control while welding.

BIG VIEWING AREA With a viewing area larger than most helmets in its class, the operator gets a better visual of the working area.

MAGNIFYING LENS HOLDERBuilt-in provision for magnifying lens*, if required. *Magnifying lens not included.

OPERATOR COMFORTHigh quality headgear - comfortable, lightweight and fully adjustable for easy adjustment to provide maximum face and neck protection. Weighs only 515g.

WELDING

M

ADE FOR

M

ADE FOR

103 CONTENTS

DUAL ARC SENSORSProvides continuous arc sensing capability. Lens automatically switches from light state 4 to adjustable welding shades 9-13 when an arc is struck. Lens darkening reaction time 1/10,000 sec.

BATTERY POWERED WITH SOLAR-ASSISTFor exceptionally long life and no charging required! Features auto on/off function and low battery indicator. Delivers up to 1500 hours of interruption free welding with MIG, Stick and Inverter power sources - meaning your helmet will always be ready to go when you are. Replaceable battery.

GRIND MODEComes standard with Grind Mode, meaning you can use one helmet for all your welding requirements - including weld preparation and clean-up.

PARTS AND ACCESSORIES

Front Lens Gasket 235758Front Cover Lens (pkt 5) 235621PReplacement Filter Lens (Indent) 770671Inside Cover Lens (pkt 5) 770237PRatchet Headgear assembly 770246Replaceable Battery 217043

STANDARDS

aS/NZS 1338.1 (auto-Darkening)aS/NZS 1337.1 B (High Impact)aNSI Z87.1-2003 (High Impact)DIN/TUV/CSa

PRODUCT SPECIFICATIONS

Part Number 235620Viewing area 97 X 46mmCartridge Size 110 X 90mmVariable Shades 9 to 13Light State 4Grind Mode Yes

Switching Speed (Light to Dark) 1/10,000 Sec

Delay Speed (Dark to Light) 0.1 – 1.0 Secarc Sensors 2Weight 515g

Power Lithium Battery & Solar-assist

On/Off Control automaticOperating Temperature -5°C to +55°C

Warranty 1 Year (auto-Darkening Lens Only)

1 YEAR WARRANTYLike all WIa products, this product is manufactured with quality in mind. Tested under stringent conditions, we provide a 1 year warranty for your peace of mind.

1 YEA

R

Not Suitable for Low Current TIG applications. Refer to Performance, Digital Elite and Titanium Helmets.

104 CONTENTS

Digital Performance™ SeriesPart No: Black - 256159, Custom 64’ - 256160

Reliable, General Purpose Welding Helmet.

BLACK CUSTOM 64’

WELDING SAFETY

LIGHTWEIGHT HEADGEAR The lightweight headgear has multiple settings to achieve the best fit and comfort.

3 YEAR WARRANTY Designed to withstand industrial environments, every Miller helmet comes with a 3 year warranty (auto-Darkening lens only).


DIGITAL CONTROLSallows the user to easily adjust mode, shade, delay and sensitivity.

THREE INDEPENDENT ARC SENSORSDigital lens and three independent arc sensors for superior arc sensing.

3 OPERATING MODESWeld, Cut and Grind.

BATTERY POWERED WITH SOLAR ASSISTTwo replaceable lithium batteries, with solar assist, deliver up to 3000 hours of use.

QUICK RELEASE COVER LENSallows for easy replacement of cover lenses.

LIGHTWEIGHTat only 482g, the helmet can be worn for long periods, keeping operator fatigue to a minimum.

AUTO ON-OFFPower control triggers lens at the strike of an arc.

MAGNIFYING LENS COMPATIBLEadd a magnifying lens* if required. available in 1.5, 2.0 and 2.5 magnification.*Magnifying lens not included.

BONUS ACCESSORIES INCLUDED: 5 outside cover lenses. 2 inside cover lenses. Helmet bag.


3 YEA

R

105 CONTENTS


Viewing area 97 x 47mm

Operating Modes 3 Modes: Weld, Cut & Grind

arc Sensors 3 Independent SensorsVariable Shades 9-13Light State 4 (all Modes)Grind Mode Shade # 3-5Cut Mode Shade # 5-9X-Mode Shade # 9-3TIG Rating 5 amps

PowerReplaceable Lithium Batteries (2); up to 3000 Hours

Switching Speed (Light-Dark) 1/20,000 Sec

Delay Speed (Dark-Light) 0.10-1.0 SecOn/Off Control automaticMagnifying Lens Holder YesWeight 482g

Warranty 3 Years (auto-Darkening Lens Only)


Front Lens Gasket 232028Front Lens Cover (5 Pk) 231921PLens Filter 256468Inside Lens Cover 770237PRatchet Headgear 256174Headband, Foam 770249Headband, Towelling 770299adjustment angle/Stop Kit 256178Helmet Carry Bag with Miller Logo 770250Magnifying Lens 1.5 Magnification 2.0 Magnification 2.5 Magnification

212238P 212240P 212242P

STANDARDS


106 CONTENTS

Digital Elite™ SeriesPart No: Black - 257213, Inferno - 257217, Lucky’s Speed Shop - 257214, Joker - 257218

BLACK INFERNO

Four Modes - Weld, Cut, Grind & X-Mode.

THE JOKERLUCKY'S SPEED SHOP

3 YEAR WARRANTYDesigned to withstand industrial environments, Miller helmets now come with a 3 year warranty (auto-Darkening lens only).

BONUS ACCESSORIES INCLUDED: 5 outside cover lenses. 2 inside cover lenses. Helmet bag.

LIGHTWEIGHT HEADGEAR The lightweight headgear has multiple settings to achieve the best fit and comfort.

FOUR INDEPENDENT ARC SENSORS Provide continuous arc sensing for the most demanding applications plus superior lens response.

SUITS A WIDE RANGE OF WELDING PROCESSESMIG, Stick, TIG, Flux Cored and Pulse.

IMPROVED DIGITAL CONTROLSallows the user to easily adjust mode, shade, delay and sensitivity.


LIGHTWEIGHTat only 510g, the helmet can be worn for long periods, keeping operator fatigue to a minimum.


MAGNIFYING LENS COMPATIBLEadd a magnifying lens if required. *Magnifying lens not included.

WELDING SAFETY

AUSTRALIAN STANDARDS 3 Y

EA

R

107 CONTENTS


Front Lens Gasket 216337

Front Lens Cover (5 Pk) 216326P

Filter Lens Gasket 234758

Filter Lens 256469

Inside Lens Cover 216327P

Lens Holder 234759

Battery Holder (Left & Right) 216339

Replacement Lithium Battery (X2) 217043

Ratchet Headgear 256174

Comfort Cushion 216336

Sweatband Towelling (5 Pk) 770299

adjustment angle/Stop Kit 256178

Lens Holder (External) 241978

Helmet Carry Bag with Miller Logo 770250

Magnifying Lens212238P 212240P 212242P


Viewing area 97 x 60mm

Operating Modes 4 Modes: Weld, Cut, Grind, X-Mode

arc Sensors 4 Independent Sensors Plus X-Mode

Variable Shades 9-13

Light State 4 (all Modes)

Grind Mode Shade 4

Cut Mode Shade 5-9

X-Mode Shade 9-13

TIG Rating 5 amps and Below

PowerReplaceable Lithium Battery up to 3000 Hours

Switching Speed (Light - Dark) 1/20,000 Sec

Delay Speed (Dark - Light) 0.10-1.0 Sec

On/Off Control automatic

Magnifying Lens Holder Yes

Weight 510g

Warranty 3 Years (auto-Darkening Lens Only)

Rec. amps GMaW (MIG) MMaW (Stick) Up to 400 amps*

Rec amps GTaW (TIG) 5-350 amps**

*X-Mode eliminates sunlight interference, intermittent sensing (pipe), low amperage lens openings (TIG) and obstructed sensors. **amperage ratings may vary for processes involving aluminium and stainless steel.

WHAT IS X-MODE?Sensors are normally triggered by the light when you strike an arc. In X-Mode, the sensors are triggered by the electromagnetic field that is created when you start a weld.

X-Mode overcomes instances where obstructions block a sensor when welding out-of-position. Even when there is an obstruction, the sensor will still trigger because of the electromagnetic field.

For outside work, X-Mode will stop the lens constantly lightening and darkening because of the light triggering the sensors. The sensors will only trigger the lens to darken when you start to weld.

DIGITAL LENS TECHNOLOGY

WELDSuits MIG, Stick, TIG, Flux Cored and Pulse welding processes. Shades 9-13.

CUTSuits Plasma, Laser, Gas welding and cutting applications. Shades 5-9.

GRINDSuits weld preparation and clean-up. Fixed shade 3.

X-MODE

Electromagnetic arc sensing technology eliminates sunlight interference, intermittent sensing (pipe), low amperage lens openings (TIG) & obstructed sensors. Shades 9-13.

STANDARDS


108 CONTENTS

Titanium SeriesPart No: Titanium 9400 - 256176, Titanium 9400i - 256177

Heavy Duty Protection.

TITANIUM™ 9400

EXCLUSIVE! INFOTRACK™ TECHNOLOGY.

TITANIUM™ 9400i

WELDING SAFETY

INTEGRATED GRIND SHIELD*Provides 180° field of view while grinding and complies with australian High Impact Standards. *Only available on 9400i model.

MAGNIFYING LENS COMPATIBLEadd a magnifying lens* if required. available in 1.5, 2.0 and 2.5 magnification. *Magnifying lens not included.

INFOTRACK™ TECHNOLOGYExclusive arc tracking technology that includes a digital clock and alarm, makes it possible to track welding time.

X-MODEWeld, cut and grind with one helmet. Plus, there’s X-Mode for outdoor or out-of-position welding.

X-Mode eliminates: Sunlight interference. Intermittent sensing - pipe. Low amperage lens

openings – TIG. Obstructed sensors.

3 YEAR WARRANTYDesigned to withstand industrial environments, the Titanium Series helmets come with a 3 year warranty (auto-Darkening lens only).

SUITS HIGH AMPERAGE APPLICATIONSThe shell reflects heat to assist in keeping the helmet and user cool, while the aluminium heat shield protects and extends the working life of the lens and helmet.

EXTERNAL GRIND CONTROL*allows the user to switch between weld and grind modes at the push of a button. *available on 9400 model only.

LIGHTWEIGHT HEADGEARThe lightweight headgear has multiple settings to achieve the best fit and comfort.



109 CONTENTS

WHAT IS INFOTRACK™?InfoTrack™ is an exclusive Miller technology which records arc-on time and provides a digital clock with the ability to set an alarm or timer.

The built-in alarm reminds operators to take a break from welding to keep fatigue to a minimum, especially important in hot environments.

Being able to record actual arc time makes it easier to know the welding time for a particular job.


TITANIUM 9400 TITANIUM 9400i

Viewing area 97 x 60mm 97 x 60mmOperating Modes Weld, Cut, Grind & X-Mode* Weld, Cut, Grind & X-Mode*arc Sensors 4 Independent Sensors Plus X-Mode 4 Independent Sensors Plus X-Mode InfoTrack™ Lens Technology Yes YesVariable Shades 9-13 9-13Light State 4 (all Modes) 4 (all Modes) Grind Mode Shade 4 Integrated Grind ShieldCut Mode Shades 5-9 Shades 5-9X-Mode Shades 9-13 Shades 9-13TIG Rating 5 amps 5 amps

Power Replaceable Lithium Batteries (2) with Solar assist: up to 3000 Hours

Replaceable Lithium Batteries (2) with Solar assist: up to 3000 Hours

Low Battery Light Red LED Shows 2-3 Days of Remaining Battery Life

Red LED Shows 2-3 Days of Remaining Battery Life

Switching Speed (Light-Dark) 1/20,000 Sec 1/20,000 Sec

Delay Speed (Dark-Light) 0.10-1.0 Sec 0.10-1.0 SecOn/Off Control automatic automaticMagnifying Lens Holder Yes YesWeight 595g 737gWarranty 3 Years (auto-Darkening Lens Only) 3 Years (auto-Darkening Lens Only)

*X-Mode eliminates sunlight interference, intermittent sensing (pipe), low amperage lens openings (TIG) and obstructed sensors.


DURABLE SHOCK- ABSORBING GASKETProtects the lens from drop impact.

BONUS ACCESSORIES INCLUDED 5 outside cover lenses. 2 inside cover lenses. Helmet bag.

110 CONTENTS

Titanium SeriesPart No: Titanium 9400 - 256176, Titanium 9400i - 256177

WELDING SAFETY


TITANIUM 9400 PART NUMBER TITANIUM 9400i PART NUMBER

Front Lens Cover (5 Pk) 216326P Lens Holder, Front 241977Lens Holder 241977 Lens Filter - With Cable 256360Lens Filter 256359 Front Lens Cover (5 Pk) 216326PInside Lens Cover 216327P Inside Lens Cover 216327PLens Holder, Front 243396 Battery Tray (Left & Right) 216339Battery Tray (Left & Right) 216339 Replacement Lithium Battery (x2) 217043Replacement Lithium Battery (x2) 217043 Lens - Grinding Shield 245818Ratchet Headgear assembly 256174 Ratchet Headgear assembly 256174Sweatband, Towelling (5 Pk) 770299 Sweatband, Towelling (5 Pk) 770299Sweatband, Foam 770249 Sweatband, Foam 770249adjustment angle/Stop Kit 256178 adjustment angle/Stop Kit 256178Helmet Carry Bag with Miller Logo 770250 Helmet Carry Bag with Miller Logo 770250Magnifying Lens1.5 Magnification 2.0 Magnification 2.5 Magnification

212238P 212240P 212242P

Magnifying Lens1.5 Magnification 2.0 Magnification 2.5 Magnification

212238P 212240P 212242P

DIGITAL LENS TECHNOLOGY (with exclusive Infotrack™ technology)




X-MODE


STANDARDS


111 CONTENTS


SCOTT, DRIVER AND FABRICATOR GARRY ROGERS MOTORSPORT



112 CONTENTS

Vortex PAPR SystemPart No: Black - 236001, Inferno - 236002

Powered Air Purifying Respirator.OFFERS RESPIRATORY PROTECTION WHEN WELDING, GOUGING OR CUTTING.

WELDING SAFETY

BLACK INFERNO


DUAL AIR SPEEDSallows the user to adjust the air volume for a variety of working conditions – 160 and 200 litres/minute.

LIGHTWEIGHT LITHIUM ION BATTERYDelivers 8 hours of operation on low setting and 6 hours on high setting. No memory retention from frequent charging. 3 hours to charge.

LIGHTWEIGHT BLOWER UNIT DESIGNFor operator comfort.

AUDIBLE AND VIBRATING ALARMSNotify the operator of blocked filters or air blockages.

BACK HARNESSEvenly distributes the weight of the unit over the entire upper body, keeping operator fatigue to a minimum when welding for long periods.

TWIST LOCK HOSE CONNECTION DESIGNEliminates air leaks and makes connecting and disconnecting quick and easy.

HOSE COVERProtects from sparks and abrasion for extended life.

LED BATTERY METERallows the operator to keep track of remaining power.


113 CONTENTS

FLOW METER allows the operator to check air volume output. This ensures the life of every filter is maximised.

MILLER’S DIGITAL ELITE AUTO-DARKENING LENSCombined with Miller’s Digital Elite™ for maximum performance - weld, cut and grind.


Battery Charger 236010Replacement Battery 236011Replacement Hose 236012Replacement Head Seal 236013Replacement Filter Cover 236014Pre-Filter (Pack 10) 236015Replacement Particle Filter 236020Replacement Belt 236030Replacement Back Harness 236031Tool Bag 236099

REPLACEABLE FILTER CARTRIDGE

OPTIONAL MAGNIFYING LENS AVAILABLE

REINFORCED HEAD SEALFor durability. Fully washable.

TOOL BAGHolds PaPR and other welding accessories.

The Vortex complies with AS/NZS 1716:2003 PAPR-P2. WIA will not take responsibility for respiratory protective equipment that is chosen incorrectly. Some welding environments may contain dangerous levels of poisonous gases that are not suitably filtered by a particle filter. Vortex is not suitable for environments that contain poisonous gases or have an oxygen deficiency. It is the purchasers’ responsibility to ensure their workplace is tested adequately for fume hazards and adequate extraction and ventilation is used in confined space applications.

COMES COMPLETE WITH

Compact Blower Unit. Miller Digital Elite™ Helmet with Head Seal. Particle Filter. Belt & Back Harness. Battery. Battery Charger. air Flow Meter. Tool Bag.

INDUSTRIAL APPLICATIONS Manufacturing. Fabrication. Stainless Steel. Flux cored.

MILLER HELMET STANDARDS


VORTEX PAPR STANDARDS

aS/NZS 1716:2003 PaPR-P2

DIGITAL LENS TECHNOLOGY




X-MODE


114 CONTENTS

Accessories

115 CONTENTS

Coolmate 3Part No: MR043007012 [115 Volt] Part No: MR043008012 [230 Volt]COOLMATE 3 (115 VAC, 50/60 HZ)For use with water-cooled torches rated up to 600 amps. Runs on 115 VaC. Unique paddle-wheel indicator, external filter and easy-fill spout. 11 litre capacity.

COOLMATE 3 (230 VAC, 50/60 HZ)For use with water-cooled torches rated up to 600 amps. Runs on 230 VaC. Unique paddle-wheel indicator, external filter and easy-fill spout. 11 litre capacity.

Coolmate 3.5Part No: MR300245Designed to integrate with the Dynasty and Maxstar 350 and 700 power sources. For use with water-cooled torches rated up to 600 amps. 13 litre capacity.

Coolmate 4Part No: MR042288015

Drive Rollers & Inlet Guides To suit S-74S & Pipeworx Dual Feeder

For use with water-cooled torches rated up to 600 amps. Runs on 115 VaC. The best performer in its class. Tough moulded polyethylene case with carrying handle. 15 litre capacity.

ACCESSORIES

Water Coolers

SIZE (mm) PART NO.0.9mm 'V' groove MR1510261.2mm 'V' groove MR1510271.6mm 'V' groove MR1510291.2mm knurled 'V' groove MR1510531.6mm knurled 'V' groove MR151055

SIZE (mm) PART NO.2.0mm knurled 'V' groove MR1510572.4mm knurled 'V' groove MR1510582.8mm knurled 'V' groove MR1510591.2mm 'U' groove MR151037

Each kit contains 4 Drive Rollers, Inlet Guide, Intermediate Guide and antiwear Guide.

116 CONTENTS

SIZE (mm) PART NO.0.6 / 0.8 W26-0/80.8 / 1.0 W26-1/80.9 / 1.2 W26-5/80.9 / 1.2 knurled W26-9/81.2 / 1.6 W26-4/81.0 / 1.2 aluminium W26-3/81.0 / 1.2 knurled W26-7/81.2 / 1.6 knurled W26-6/80.8 / 0.9 ‘V’ groove W26-8/8

DRIVE ROLLERS To suit W32, W52, W53, W55, CP42, CP44-3, CP102, CP103, CP104, CP105, CP106, CP109, CP110, CP111, CP112, CP113-1, CP115, CP116, CP120-1, CP121-0, CP122-1 & CP131

SIZE (mm) PART NO.2.0 I.D. brass W26-0/13

INLET GUIDES

SIZE (mm) PART NO.1.2 nylon wire guide for aluminium MR1512031.6mm nylon wire guide for aluminium MR151205

NYLON INLET GUIDES For Miller 2RD wirefeeders

SIZE (mm) PART NO.0.6 ‘V’ groove MR0871310.8 ‘V’ groove MR0795940.9 ‘V’ groove MR0795950.9 / 1.2 ‘V’ groove MR1903001.2 ‘V’ groove MR0795961.6 ‘V’ groove MR0795980.9 ‘U’ groove MR0447491.2 ‘U’ groove MR0795991.6 ‘U’ groove MR0796010.9 knurled ‘V’ groove MR0796061.2 knurled ‘V’ groove MR0796071.6 knurled ‘V’ groove MR0796092.0 knurled ‘V’ groove MR0796101.2 cogged ‘U’ groove MR0833181.6 cogged ‘U’ groove MR079614

DRIVE ROLLERS To suit W19, W37, 22a, S-22a, S-32S & Suitcase 12VS

*Each drive roll kit includes top & bottom drive rollers & wire guide.

SIZE (mm) PART NO.0.6 / 0.8 ‘V’ groove W51-0/50.8 / 1.0 ‘V’ groove W51-0/40.9 / 1.2 ‘V’ groove W51-0/21.2 / 1.6 knurled W51-0/11.6 / 2.0 knurled W51-0/70.9 / 1.2 aluminium W51-0/3

DRIVE ROLLERSTo suit W41, W56, CP118, CP119, CP44-4, CP113-3, CP114 & CP120-3

SIZE (mm) PART NO.0.6 / 0.8 ‘V’ groove WF0260.9 / 1.2 ‘V’ groove WF0271.2 / 1.6 ‘V’ groove WF0281.0 / 1.2 aluminium WF0290.9 / 1.2 knurled WF0301.2 / 1.6 knurled WF031

DRIVE ROLLERS To suit W64, W60 & W61 Wirefeeders (37mm dia) CP124, CP125, CP126, CP127, CP130, CP132, CP133, CP134 & CP135

DRIVE ROLLERSTo suit W14, W17, W21 & W35 Wirefeeder

SIZE (mm) PART NO.

40 O.D. 12 I.D.0.8 ‘V’ groove W2-210.9 / 1.2 ‘V’ groove W2-22Flat upper roller W2-200.9 / 1.2 ‘U’ groove, chromed W2-481.2 / 1.6 ‘U’ groove, chromed W2-50Flat upper roller, chromed W2-491.2 knurled W2-511.6 / 2.0 knurled W2-24

SIZE (mm) PART NO.0.8 / 1.2 brass W2-44/12-11.6 / 2.0 brass W2-44/12-2

INLET GUIDES

ACCESSORIES

Drive Rollers & Inlet Guides

117 CONTENTS

Remote Hand ControlPart No: MR300430 [Includes 14-Pin Receiver]

Remote Foot ControlPart No: MR300429 [Includes 14-Pin Receiver]

NO CORDS – IMPROVES SAFETY AND REDUCES MAINTENANCE TIME

IMPROVES PRODUCTIVITYallows parameter adjustments up to 91 metres away from welder without returning to the machine or calling for assistance.

SMART™ TOUCH BUTTONSIncreases or decreases machine parameters in one or five percent increments, for quick and accurate adjustments.

EASY TO INSTALL RECEIVERPlugs directly into the 14-pin receptacle of Miller machines.

NO CORDS – IMPROVES SAFETYEliminates control cord and reduces potential trip hazard.

IMPROVES PRODUCTIVITY & MANOEUVRABILITYEliminates cord tangles, reduces clean up time and work area cord clutter.

EASILY PROGRAMMABLEControl can be quickly and easily paired with any other Miller 14-pin wireless receiver. (Control is pre-programmed when purchased with the receiver).

MULTIPLE FREQUENCY SHARINGallows up to 20 systems to operate in a 27.4m radius with accuracy and precision - and without delay or system interference.

IMPROVES RELIABILITYEliminates control cord failure.

EXTENDS WELDING RANGE TO 27.4M

IMPROVES WELD QUALITY WITH PRECISE OPERATOR CONTROL

ACCESSORIES

AUTO ON TO MAXIMISE BATTERY LIFE UP TO 250 HOURS

1 YEAR WARRANTY

EXTENDS WELDING RANGE TO 91M

IMPROVES WELD QUALITY WITH PRECISE OPERATOR CONTROL

DIGITAL METER DISPLAY

EASY TO USE

LONG BATTERY LIFE

1 YEAR WARRANTY

Remote Controls

118 CONTENTS

119 CONTENTS

MIG Gun & Consumables FOR QUALITY WELDS & INCREASED PRODUCTIVITY.

120 CONTENTS

MIG GUNS

MILLER SELF SHIELDED GUN (MILLER DIRECT CONNECT)

The Ironmate™ Guns (350amp, 4.6m) are for feeding self-shielded (gasless) flux cored wires. They are an ideal match for Miller Suitcase® wirefeeders. MR195729

MILLER PUSH PULL MIG GUN (SUITS MILLER MPA SERIES WIRE FEEDERS ONLY)

XR aluma Pro Plus Gun, 7.6m - This easy-to-use and easy-to-maintain gooseneck-style MIG gun is designed for push-pull wire feed systems. available in air- cooled. Trigger hold feature reduces operator fatigue. Gun design allows for better access into tight spots.

MR300001001

Miller MIG Guns

MIG Guns

Note: Requires kit MR230669 to accept standard Bernard Centrefire consumables.

121 CONTENTS

BERNARD™ Q150 GUN (180 AMP @ 35% DUTY) FITTED WITH CENTERFIRE COMPONENTS

Gun with fixed short 45 deg. neck, 3m cable, 0.9 tip, Euro BEQ1510aO8CEBERNARD™ Q200 GUN (240 AMP @ 35% DUTY) FITTED WITH CENTERFIRE COMPONENTS

Gun with fixed short 45 deg. neck, 3.6m cable, 0.9 tip, Euro BEQ2012aO8CEBERNARD™ Q300 GUN (390 AMP @ 35% DUTY) FITTED WITH CENTERFIRE COMPONENTS

Gun with rotatable short 45 deg. neck, 3m cable, 0.9 tip, Euro BEQ3010aB8CEGun with fixed medium 45 deg. neck, 3.6m cable, 0.9 tip, Euro BEQ3012aR8CEGun with rotatable short 45 deg. neck, 4.6m cable, 0.9 tip, Bernard BEQ3015aB8CBGun with rotatable short 45 deg. neck, 4.6m cable, 0.9 tip, Euro BEQ3015aB8CEBERNARD™ Q400 GUN (440 AMP @ 35% DUTY) FITTED WITH CENTERFIRE COMPONENTS

Gun with rotatable long 45 deg. neck, 3m cable, 0.9 tip, Bernard BEQ4010aH8EBGun with fixed medium 45 deg. neck, 3m cable, 0.9 tip, Euro BEQ4012aR8EEGun with fixed medium 45 deg. neck, 3.6m cable, 1.2 tip, Miller BEQ4012aR8EMGun with rotatable long 45 deg. neck, 4.6m cable, 1.2 tip, Bernard BEQ4015aH8EBGun with rotatable long 45 deg. neck, 4.6m cable, 1.2 tip, Euro BEQ4015aR8EEGun with rotatable long 45 deg. neck, 4.6m cable, 1.2 tip, Miller BEQ4015aH8EM

BERNARD 250 & 350 PIPEWORX GUNS – FITTED WITH CENTREFIRE COMPONENTS

Bernard Pipewox 250-15, 4.6m cable, 1.2mm tip, Miller (recommended for root pass welding only) MR195399Bernard Pipeworx 350-15, 4.6m cable, 1.2mm tip, Miller MR195400

MIG GUNS

Bernard™ MIG Guns

The Bernard™ Difference

Bernard™ MIG guns have been designed and manufactured to suit the most demanding industrial welding applications. Investing in a high quality MIG gun means less downtime for maintenance, component changeovers and more consistent welds – resulting in lower costs and better productivity. The Bernard™ brand is trusted by customers to deliver on ease of use, durability, performance and quality.

122 CONTENTS

CONSUMABLES

Consumables & Replacement Parts

Centerfire™ Consumables

No tools required to replace tip or nozzle. “Drop-In” tip with no

threads means quick change after burnback, reducing down time. Large diameter tip base

and tapered seat provides better electrical conductivity and heat transfer.

Spatter shield within nozzle protects diffuser and gives smoother, less turbulent gas flow. Solid, concentric

relationship between tip and nozzle keeps tip centered even after hard use... and abuse. Threaded nozzle holds tip

fixed at 1/4” or 1/8” recess, flush, or 1/8” stick out.

A CLEAR CUT DIFFERENCE Less expensive consumables don’t necessarily add up to cost savings.

It’s important to choose longer lasting consumables. They can make the difference between repeated consumable replacement and rework, or more arc time and a better bottom line.

Centerfire™ contact tips, nozzles and diffusers are eay-to-use and high performing - they provide better arc starts, less spatter and more consistent welds - and also last up to three times longer than competitor brands.

Compatible with all standard air-cooled Bernard™ Q-Gun and S-Gun series. Complete family of

tips and nozzles is available to meet most of your welding needs.

123 CONTENTS


Contact TipsSHORT CONTACT TIPS - STANDARD - 7400 SERIES (ONLY AVAILABLE IN PACKETS OF 10)

0.6mm (0.024”) (packet of 10 tips) BE74970.8mm (0.030”) (packet of 10 tips) BE74880.9mm (0.035”) (packet of 10 tips) BE74891.0mm (0.039”) (packet of 10 tips) BE74961.2mm (0.045”) (packet of 10 tips) BE74901.3mm (0.051”) (packet of 10 tips) BE74981.6mm (0.063”) (packet of 10 tips) BE74912.0mm (0.078”) (packet of 10 tips) BE74922.4mm (0.094”) (packet of 10 tips) BE7493LONG CONTACT TIPS - STANDARD - 1500 SERIES (ONLY AVAILABLE IN PACKETS OF 10)

0.9mm (0.035”) (packet of 10 tips) BE15891.0mm (0.040”) (packet of 10 tips) BE15961.2mm (0.045”) (packet of 10 tips) BE15901.4mm (0.052”) (packet of 10 tips) BE15981.6mm (0.062”) (packet of 10 tips) BE1591CONTACT TIPS - CENTERFIRE™ - STANDARD (ONLY AVAILABLE IN PACKETS OF 10)

0.8mm (0.030") standard tip (packet of 10 tips) BET-0300.9mm (0.035") standard tip (packet of 10 tips) BET-0351.0mm (0.039") standard tip (packet of 10 tips) BET-0391.2mm (0.045") standard tip (packet of 10 tips) BET-0451.4mm (0.052") standard tip (packet of 10 tips) BET-0521.6mm (0.0625") standard tip (packet of 10 tips) BET-0622.0mm (0.078") standard tip (packet of 10 tips) BET-0782.4mm (0.094") standard tip (packet of 10 tips) BET-094CONTACT TIPS - CENTERFIRE™ - TAPERED (ONLY AVAILABLE IN PACKETS OF 10)

0.9mm (0.035”) tapered tip (packet of 10 tips) BETT-0351.2mm (0.045”) tapered tip (packet of 10 tips) BETT-0451.4mm (0.052”) tapered tip (packet of 10 tips) BETT-0521.6mm (0.062”) tapered tip (packet of 10 tips) BETT-062PIPELINE SERIES PARTS - STANDARD (ONLY AVAILABLE IN PACKETS OF 10)

Tip Pipeline 0.9mm - Standard (packet of 10 tips) BE4281Tip Pipeline 1.2mm - Standard (packet of 10 tips) BE4282Tip Pipeline 0.9mm - Long (packet of 10 tips) BE4381aTip Pipeline 1.2mm - Long (packet of 10 tips) BE4382aNozzle Brass Pipeline & Insulator - Standard BE4295Nozzle Brass Pipeline & Insulator - Long BE4395a

124 CONTENTS

CONSUMABLES


NozzlesBERNARD NOZZLES - STANDARD SERIES

Nozzle Copper Water Cooled BE1101QDNozzle Brass w/insulator BE4391Nozzle Brass Tapered w/insulator BE4392Nozzle Copper w/insulator BE4393Nozzle Copper Tapered w/insulator BE4394Nozzle Brass w/insulator 400a BE4491Nozzle Brass Tapered w/insulator 400a BE4492Nozzle Copper w/insulator 400/500a BE4591Nozzle Copper Tapered w/insulator BE4592BERNARD NOZZLES - CENTERFIRE SERIES

Nozzle Small Brass Tapered 3/8” Diameter - Flush BENST-3800BNozzle Small Brass Tapered 3/8” Diameter - 1/8 Recess BENST-3818BNozzle Small Brass 1/2” Diameter - Flush BENS-1200BNozzle Small Brass 1/2” Diameter - 1/8 Recess BENS-1218BNozzle Small Copper 1/2” Diameter - 1/8 Recess BENS-1218CNozzle Small Brass 5/8” Diameter - Flush BENS-5800BNozzle Small Brass 5/8” Diameter - 1/8 Recess BENS-5818BNozzle Small Copper 5/8” Diameter - 1/8 Recess BENS-5818CNozzle Copper 5/8” Diameter - Flush BEN-5800CNozzle Brass 5/8” Diameter - Recess BEN-5814BNozzle Copper 5/8” Diameter - 1/4 Recess BEN-5814CNozzle Brass 5/8” Diameter - 1/8 Recess BEN-5818BNozzle Copper 5/8” Diameter - 1/8 Recess BEN-5818CNozzle Copper 3/4” Diameter - Flush BEN-3400CNozzle Brass 3/4” Diameter - 1/4 Recess BEN-3414BNozzle Copper 3/4” Diameter - 1/4 Recess BEN-3414CNozzle Brass 3/4” Diameter - 1/8 Recess BEN-3418BNozzle Copper 3/8” Diameter Flush Tapered BENT-3800CBERNARD NOZZLES - NEW HEAVY DUTY CENTERFIRE SERIES

Nozzle Cone 3/4” Diameter - 1/4 Recess BEHDN-3414Nozzle Cone 3/4” Diameter - 1/8 Recess BEHDN-3418Nozzle Cone 5/8” Diameter - 1/4 Recess BEHDN-5814Nozzle Cone 5/8” Diameter - 1/8 Recess BEHDN-5818Nozzle Body BEN-HDC

125 CONTENTS


Head Assemblies & DiffusersHEAD ASSEMBLIES (DIFFUSERS)

Head 200/300a for short tip BE4335Head 200/300a for short tip Tweco to Bernard adaptor BE4335THead 200/300a for long tip BE4235Head 350/400/500a for short tip BE4435Head 350/400/500a for short tip - Tweco to Bernard adaptor BE4435THead 600a for long tip BE4635Head 600a for long tip - with liner guide BE4635-116DIFFUSERS (HEADS) FOR CENTERFIRE SERIES

Diffuser, small BEDS-1Diffuser, small conversion, Tweco 4, Tregaskiss BEDS-1TDiffuser, large BED-1Diffuser, large conversion, Tweco 4, Tregaskiss BED-1TDiffuser, large conversion, Tweco 5 BED-1T5

LinersLINERSAMPS200 - 400 a Liner Steel 0.9-1.2mm BE43115

Liner Nylon 0.9-1.2mm BE43115XLiner Steel with Nylon Core 0.9-1.2mm BE1920218

300 - 400 a Liner Steel 2.0mm BE1920356300 - 600 a Liner Steel 1.2-1.6mm - 4.6m BE44215

Liner Nylon 1.2-1.6mm - 4.6m BE44215N400 - 600 a Liner Steel 0.9-1.2mm - 4.6m BE44115500 - 600 a Liner Steel 2.0mm - 4.6m BE44315

Liner Steel 2.4mm - 4.6m BE45415Liner Steel 2.8mm - 4.6m BE45615Liner Steel 3.2mm - 4.6m BE46715Jump Liner 1.6mm BEQJL-116Jump Liner 0.9/1.2mm BEQJL-3545

ALUMINIUM LINER GUIDES

Liner guide suit W17 & W35 Feeders, 0.9 - 1.2 mm BE2760002

126 CONTENTS

CONSUMABLES


AdaptorsADAPTORS FOR CENTERFIRE SERIES

Adaptor, Tweco 180/200 & Magnum 250 to Centerfire BE1380005Adaptor, Tweco Eliminator 250/350 to Centerfire BE1380012Adaptor, Tweco Eliminator 450/600 to Centerfire BE1380017

WIRE FEEDER ADAPTORS

Gun End Conversion

Bernard Quick Connect adaptor BE1199Euro adaptor BE1199EMiller adaptor BE1199MWire Drive Conversion

adaptor W37/W19 wirefeeder (Miller to Euro) MR164902Bernard™ Quick Connect Fitting BE4920Miller/EZ feed adaptor BE4995N

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Kits & AssembliesGASLESS PARTS - HEAVY DUTY CENTERFIRE SERIES

Insulator BE7010024HANDLE KITS

Handle kit to suit 150a guns - horizontal split BE1880194Handle kit suit 200/300/350a guns BE1780006Handle kit suit 400/500a guns BE4408Handle kit to suit 200/300/400a guns (curved handle) BE1880155TRIGGER ASSEMBLIES

Switch assembly for 180a guns (eg. BEQ1510a07CE) BE2620054Trigger assembly microswitch to suit 200/300/350a guns BE5662Trigger assembly copper brass contacts to suit 200/300/350a guns BE5662YTrigger assembly to suit 400/500a guns BE4422Locking trigger BE5662LCONE NUT REPAIR KITS

Cone nut suit 300/350a (wirefeeder end) BE1983Cone nut suit 400a (wirefeeder end) BE1984Plastic nut cover, slip on BE1840057Cone nut BE4305

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CONSUMABLES


O’RingsGENUINE BERNARD O’RING

O’ring for 4235 & 4335 head BE7126O’ring for 4435 & 4635 head BE7127O’ring (small) for Euro end BE9165O’ring (large) for Euro end BE4421O’ring (gas pin QD) BE4907O’ring Miller end MR079974

Strain Relief

CapsCAPS

Cap insulator, 300a BE4323Cap insulator, 400a BE4423Cap insulator, 400A Centerfire BE10012

STRAIN RELIEF

Strain relief (suits old style guns) BE1880074Suits Q200/300 guns BE2520033Suits Q400 guns BE2520041Strain relief suit 150a guns (suits new euro) BE2520047Strain relief rigid universal BE2520069

129 CONTENTS


GUN ACCESSORIES (MISCELLANEOUS)

Hang up hook kit BE1790002Plastic nut cover, slip on BE1840057Bakelite body QD cable end BE4901Feeder tip 1.3/3.2mm (Miller ended gun) BE4474Feeder tip 0.6/1.2mm (min buy 10) (Miller ended gun) BE4477Guide tube 0.8-1.3mm 214mm BE478Insulator hex nut BE4780

Miscellaneous Accessories

130 CONTENTS

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